Front Sealing Flange

Front Sealing Flange

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

• Sealant, refer to the electronic parts catalog ETKA

Removing

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

- Toothed belt, removing. Refer to => [ Toothed Belt Drive, without Divided Toothed Belt Guard Overview ] Toothed Belt Drive, Without Divided Toothed Belt Guard Overview.

- Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with the (3415).






- Remove the crankshaft-toothed belt sprocket center bolt - 1 - - 2 - and remove the toothed belt sprocket.






- Remove diamond disc - 3 - from toothed belt gear.

- Remove the bolts - 1 through 10 -.






- Pry off and remove front sealing flange.

- Drive out the seal from the removed flange.

Installing

• Tightening specifications, refer to => [ Front Sealing Flange Overview ] Front Sealing Flange Overview

• Place a rag over open part of oil pan.

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

Wear safety glasses.

- Remove sealant residue from sealing flange for example with a rotating plastic brush.






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

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






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






- Apply a thin bead of sealant - arrow - to the clean sealing surface of the sealing flange, as shown in the illustration.






• Thickness of sealant bead: 2 to 3 mm.

Risk of plugging oil pump strainer with excess sealant.

• Do not apply sealant bead thicker than indicated.

• The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

- 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.

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

- Tighten sealing flange bolts in 3 stages as follows:






- Install bolts - 1 through 10 - and tighten by hand.

- Tighten bolts - 1 through 6 - in a diagonal sequence in stages.

- Tighten bolts - 7 through 10 -.

- Install the crankshaft seal -belt pulley side- => [ Installing ] Service and Repair.

- Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.






• Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil.

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

- Use the (3415) to tighten crankshaft toothed belt gear.






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

How to install toothed belt and adjust valve timing. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.

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

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