Front sealing flange, removing and installing

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Crankshaft Holder 3242

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Crankshaft Holder 3242

Fig 2: Thrust Piece T40007

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Thrust Piece T40007
Hand drill with plastic brush attachment
Protective glasses
Silicone sealant

Removing

Remove front bumper → 63 - BUMPERS .
Remove lock carrier → 50 - BODY - FRONT .
Remove ribbed belt → Ribbed belt, removing and installing

Fig 3: Removing Tension Roller For Ribbed Belt

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Remove tension roller for ribbed belt - arrow -.
Remove cover for lower idler pulley.

Fig 4: Removing Lower Idler Pulley For Ribbed Belt

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Remove lower idler pulley for ribbed belt - arrow -.
Remove upper toothed belt guard at left and right.

CAUTION: Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

Turn crankshaft at center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 5 5 marking.

Fig 5: Identifying Notch Aligns With Marking

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Notch - B - aligns with marking - A -.

NOTE:

Turning over the engine is performed at the center bolt of the crankshaft.

Check position of camshafts:

Fig 6: Identifying Large Holes On Securing Plates At Camshaft Gears Aligns On Inside

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The large holes - arrows - on securing plates at camshaft gears must align on inside.

In case they do not align, turn one more rotation.

Fig 7: Disconnecting Water Pipe From Oil Pan

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Disconnect water pipe - arrow - from oil pan.

Fig 8: Disconnecting Water Pipe From Engine Block

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Disconnect water pipe from engine block - arrow -.

Fig 9: Removing Locking Bolt Of TDC Marking At Upper Part Of Oil Pan

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Remove locking bolt - arrow - of TDC marking at upper part of oil pan.

NOTE:

In the crankshaft, a TDC bore is located exactly behind locking bolt (can be felt by touch).

CAUTION: Do not rotate crankshaft while touching TDC mark with finger - danger of injury.

Fig 10: Installing Crankshaft Holder 3242 In Hole For Removed Locking Bolt

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Install crankshaft holder 3242 in hole for removed locking bolt.

Fig 11: Removing Vibration Damper Of Crankshaft After Removing 8 Attachment Bolts

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Remove vibration damper of crankshaft after removing 8 attachment bolts - 1 -.
Remove center toothed belt cover.

Fig 12: Removing Mounting Bolts And Torque Support

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Remove mounting bolts - arrows - and remove torque support.

Fig 13: Removing Bracket For Torque Support Valve N382

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Remove bracket for torque support valve N382 - arrows -.
Toothed belt, removing → Toothed belt, removing and installing .

Fig 14: Removing/Installing Center Bolt For Crankshaft Toothed Belt Gear

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Remove center bolt - 2 - for crankshaft toothed belt gear - 1 -.
Remove toothed belt gear.

Fig 15: Removing Eccentric Roller & Tensioning Lever With Tensioning Roller And Tensioner

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Remove eccentric roller - 3 - , tensioning lever with tensioning roller - 2 - and tensioner - 1 -.

Fig 16: Removing/Installing Spray Jet Valve & Bolts

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Remove spray jet valve - 2 -.
Remove bolts - 1 -.
Remove lower section of oil pan → Oil Level Thermal Sensor G266 , removing and installing .

Fig 17: Removing/Installing Sealing Flange Bolts

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Remove bolts - 1 - and - 2 -.
Remove front sealing flange.
Drive out seal from removed flange.

Fig 18: Removing/Installing Thrust Washer From Crankshaft

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Mark front surface of thrust washer - arrow - using a waterproof felt pen.
Remove thrust washer from crankshaft.

NOTE:

Illustration is shown with sealing flange installed.

Installing

NOTE:

Replace gaskets, seals and O-rings.

Place a rag over open part of oil pan.
Carefully remove remaining sealant at upper part of oil pan.

Fig 19: Removing Sealant Remains On Sealing Flange With Rotating Plastic Brush

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Remove remaining sealant on sealing flange using e.g. a rotating plastic brush.

CAUTION: Wear safety glasses.

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

Fig 20: Cutting Tube Nozzle At Front Marking

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Cut tube nozzle at front marking (jet dia. approx. 1 mm).

Fig 21: Placing New Sealing Ring Onto Cylinder Block & Applying Thin Silicone Sealing Bead Each Between Cylinder Block And Upper Part Of Oil Pan

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Place new sealing ring - 1 - onto cylinder block.
Apply thin silicone sealing bead - arrows - each between cylinder block and upper part of oil pan.

Fig 22: Thinly Coating Lower Sealing Surface At Sealing Flange With Silicone Sealant

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Thinly coat lower sealing surface at sealing flange with silicone sealant (hatched area).

NOTE:

The sealing flange must be installed within 5 minutes after application of silicon sealant.

Carefully slide sealing flange onto reamed bolt at cylinder block.

Fig 23: Removing/Installing Spray Jet Valve & Bolts

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Tighten bolts - 1 - and spray jet valve - 2 -.

Fig 24: Removing/Installing Sealing Flange Bolts

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Tighten bolts - 1 - and - 2 -.
Install oil pan (lower part) → Oil Level Thermal Sensor G266 , removing and installing .
Do not oil sealing lip and outer edge of seal before pressing in.

Fig 25: Removing/Installing Thrust Washer From Crankshaft

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Press in sealing ring using thrust piece T40007 and center bolt. Rotate thrust washer and install on crankshaft.

NOTE:

The thrust washer is rotated so that the new sealing ring runs on new sealing path.
Marked front surface of thrust washer must now point toward engine.

Fig 26: Removing/Installing Center Bolt For Crankshaft Toothed Belt Gear

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Install toothed belt gear of crankshaft - 1 - with new center bolt - 2 -.

NOTE:

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.
Note washer below tensioning lever.

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

NOTE:

Secure all hose connections using hose clamps appropriate for the model type .

Install toothed belt (adjust timing) → Toothed belt, removing and installing .
Install lock carrier with attachments → 50 - BODY - FRONT .
Install torque support → Torque support (with torque support valve N382), assembly overview .

Torque specifications

Component			Nm
Front sealing flange to cylinder block			14 ¹⁾
Spray jet valve to cylinder block			35
Front sealing flange to upper part of oil pan			14
Baffle plate to front sealing flange			10
Tensioner to front sealing flange			10
Tensioning lever to front sealing flange			20 + 90° ¹⁾²⁾
Eccentric roller to front sealing flange			45
Toothed belt sprocket to crankshaft			200 + 180° ¹⁾³⁾
Torque support bracket to cylinder block			43
Upper idler pulley for ribbed belt to torque support bracket			10
Lower idler pulley for ribbed belt to front sealing flange			23
Tension roller for ribbed belt to upper part of oil pan			43

¹⁾ Replace bolt
²⁾ 90° Corresponds to a quarter turn.
³⁾ 180° Corresponds to one half rotation.