Front Engine Plate: Service and Repair

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items required

• Counter Support (3415)

• Assembly Tool (T10053)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Flat Scraper

• Silicone Sealant (D 176 404 A)

Removing

- Remove the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.

- Remove the crankshaft toothed belt gear. Secure the gear using the counter support (3415).






- Remove the oil pan, refer to the following:

Engine code CJAA, refer to => [ Oil Pump and Oil Pan Overview ] Service and Repair.

- Remove the sealing flange bolts.

- Remove the sealing flange. If necessary, loosen it by tapping it lightly with a rubber mallet.

- Remove any sealant residue from the cylinder block with a flat scraper.


Wear safety glasses.

- Remove any sealant residue from the sealing flange using a rotating plastic brush (wear safety glasses).






- Clean the sealing surfaces. They must be free of oil and grease.

Installing

• Note the expiration date of the silicone sealant (D 176 404 A).

• The sealing flange must be installed within 5 minutes after applying the silicone sealant (D 176 404 A).

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).






• The sealant bead must not be thicker than 2 to 3 mm.

• The extra sealant will get into the oil pan and can clog up the intake line for the oil pump.

• Do not let the sealant drip onto the sealing surface of the crankshaft seal.

• Before applying the bead of sealant, cover the sealing surface on the seal with a clean cloth

- Apply a bead of silicone sealant to the surface of the sealing flange as illustrated.






- Install the sealing flange immediately and tighten all bolts lightly.

• To position the sealing flange with the seal installed, use the guide sleeve (T10053/1).

- Tighten the sealing flange bolts in a diagonal sequence:

• Tightening specifications, see - item 7 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.

- Install the crankshaft toothed belt gear:

• Tightening specification, see - item 2 - in the => [ Toothed Belt Overview ] Toothed Belt Overview.

- Install the oil pan, refer to the following:

Engine code CJAA, refer to => [ Oil Pump and Oil Pan Overview ] Service and Repair.

• After installing, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

- Install and tension the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.