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 glasses

• Sealant

Removing

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

- Toothed belt, removing. Refer to => [ Toothed Belt Component Overview ] Testing and Inspection.

- 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

• 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.

• 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 -.





• 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).

- Fasten bolts in specified order:





- Tighten bolts - 1 to 6 -.

- Tighten bolts - 7 to 10 -.

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

- Replace center bolt for toothed belt sprocket.

• 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 ] Service and Repair

- Install crankshaft belt pulley. Refer to => [ Crankshaft Pulley ] Crankshaft Pulley

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

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

- 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.

Tightening Specifications





• The threads and shoulder must be free of oil and grease.