Front Engine Plate: Service and Repair

Front Sealing Flange

Special tools, testers and auxiliary items required

• Counter-Holder Tool (3415)

• Assembly Tool (T10053)

• Torque Wrench (V.A.G 1331)

• Torque Wrench (V.A.G 1332)

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant

Removing

- Bring lock carrier into service position. Refer to => [ Lock Carrier, Moving into Service Position ] Lock Carrier, Moving Into Service Position.

- Open the quick-release fasteners - arrows - and remove the engine cover.





• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.





- Move the tensioning element in direction of - arrow - to release the tension on the ribbed belt.

- Remove ribbed belt.

- Remove bolt - arrow - and disconnect the ribbed belt idler roller.





- Toothed belt, removing. Refer to => [ Toothed Belt ] Service and Repair.





- Remove crankshaft toothed belt sprocket, securing the toothed belt sprocket with Counter-Holder Tool (3415).

- Remove bolts - 1 to 10 -.





- Remove front sealing flange.

- Drive out the seal from the removed flange.

Installing

• Place a rag over open part of oil pan.

- Carefully remove any sealant residue from the cylinder block and oil pan.

CAUTION!
Wear safety glasses.

- Remove sealant residue from sealing flange e.g. with a rotating plastic brush.





- Clean sealing surfaces, they must be free of oil and grease.

- Cut tube nozzle at front marking (nozzle dia. approximately 2 mm).





- Apply a thin bead of sealant to the edge between cylinder block and oil pan - arrow -.





- Apply sealant bead - arrow - on clean sealing surface of sealing flange as shown in illustration.





• Thickness of sealant bead: 2 to 3 mm in dial.

• Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

- Lightly coat the lower sealing surface of the sealing flange with sealant - shaded area -.





• The sealing flange must be installed within 5 minutes of being applied with sealant.

- Carefully slide sealing flange onto reamed bolt at cylinder block.

- Fasten bolts in the specified order:





- Tighten bolts - 1 to 6 -.

- Tighten bolts - 7 to 10 -.

- Install the crankshaft seal belt pulley side. Refer to => [ Crankshaft Seal, Belt Pulley Side ] Service and Repair.

- Replace center bolt for toothed belt pulley.





• There must be no oil on the contact surface between the toothed belt sprocket and crankshaft.

• Do not oil the bolt for crankshaft toothed belt sprocket.

- Install the crankshaft toothed belt sprocket, counter-holding the toothed belt sprocket with Counter Support (3415).

The rest of the installation is in reverse order of removal, note the following:

- Install toothed belt (adjust timing) => [ Installing (Adjusting valve timing) ] Service and Repair.

- Install vibration damper. Refer to => [ Vibration Damper ] Vibration Damper.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support

- Place the torque support stop on the rubber buffer and tighten the nuts - arrows -.





- Install front bumper cover.

- Check headlamp adjustment.

Tightening Specifications





* Replace bolt.

* 90° corresponds to one quarter rotation.