Operation CHARM: Car repair manuals for everyone.

Front Engine Plate: Service and Repair



Sealing flange - belt pulley end, removing and installing





Special tools, testers and auxiliary items required
^ Counter support 3415
^ Assembly device T10053
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Hand drill with plastic brush
^ Silicone sealing compound D 176 404 A2
^ Flat scraper
^ Protective goggles

Removing
- Remove toothed belt.





- Remove crankshaft toothed belt sprocket. Counterhold sprocket with counter support 3415.
- Remove tensioning roller.
- Remove bolts from front sealing flange
- Release flange using light blows with a rubber headed hammer if necessary.
- Remove crankshaft seal.
- Remove sealant residue on cylinder block with a flat scraper.





- Remove sealant remains on sealing flange with a rotating plastic brush (wear eye protection).
- Clean sealing surfaces. They must be free of oil and grease.

Installing

Note:
^ Observe the use by date of the sealing compound.
^ The sealing flange must be installed within 5 minutes of applying the silicone sealing compound.





- Cut off tube nozzle at forward marking (approx. 3 mm diameter nozzle).
- Apply silicone sealing compound, as shown, to clean flange sealing surface.

Sealant bead must be:
^ 2...3 mm thick.
^ Run bead along inner side of bolt holes - arrows-.

Note:
^ The sealing compound bead must not be thicker, otherwise excessive sealing compound will enter the oil pan and may block the oil suction pipe strainer.

- Install sealing flange immediately and lightly tighten all bolts.
- Tighten sealing flange securing bolts using alternate sequence.
- Tightening torque: 15 Nm
- Remove excess sealing compound.
- Install tensioning roller.

Note:
^ The sealant must be allowed to cure for approx. 30 minutes after fitting the oil sump. Only then fill engine oil.

- Install a new seal for crankshaft - belt pulley end.





- Install crankshaft toothed belt sprocket. Counterhold sprocket with counter support 3415.
- Tighten new center bolt.
- Tightening torque: 90 Nm plus 1/4 turn (90°)

Note:
^ Center bolt thread and shoulder must be free of oil and grease.

- Install and tension toothed belt.