Timing Cover: Service and Repair
Front sealing flange, removing and installing
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 glasses
^ Sealant
Removing
- Remove ribbed belt.
- Remove Toothed belt.
- Loosen toothed belt crankshaft sprocket by holding sprocket with Counter Support 3415.
- Remove toothed belt crankshaft sprocket center bolt - 1 - and remove sprocket - 2 - and diamond disc - 3 -.
- Remove bolts - 1 to 10 -.
- Pry off and remove front sealing flange.
- Drive out seal from removed flange.
Installing
Note:
^ Place a rag over open part of oil pan.
- Carefully remove any sealant residue from 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 off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).
- Apply a thin bead of sealant to edge between cylinder block and oil pan - arrow -.
- Apply a thin bead of sealant - arrow - to clean sealing surface of sealing flange, as shown in the illustration.
^ Thickness of sealant bead: 2 to 3 mm.
Note:
^ 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 lower sealing surface of sealing flange with sealant - shaded area -.
Note:
^ The sealing flange must be installed within 5 minutes of being applied with sealant.
- Carefully slide sealing flange onto reamed bolt at cylinder block.
Note:
^ To install the sealing flange with installed seal, use the guide sleeve T10053/1.
- Fasten bolts in specified order:
- Tighten bolts - 1 to 6 -.
- Tighten bolts - 7 to 10 -.
- Install crankshaft seal (belt pulley side).
- Replace center bolt for toothed belt sprocket.
Note:
^ There must be no oil on the contact surface between the toothed belt sprocket and crankshaft.
^ Do not oil bolt for crankshaft toothed belt sprocket.
- Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.
- Hold toothed belt crankshaft sprocket with Counter Support 3415 and tighten.
The rest of installation is in reverse order of removal, note the following:
How to install toothed belt and adjust valve timing refer to Toothed belt, removing and installing.
- Install crankshaft belt pulley.
- Install ribbed belt.
- Install lock carrier with attachments.
- Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
- Install front bumper cover.
- Check headlight adjustment.
Torque Specification:
