Front sealing flange with crankshaft seal, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Pin Wrench 3212

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin wrench 3212

Fig 2: Assembly Tool T40048

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Assembly tool T40048
Hand drill with plastic brush attachment
Protective glasses
Sealant

Removing

Remove vibration damper → Vibration damper, removing and installing .
Remove ribbed belt pulley from coolant pump.

Fig 3: Locating Bolts And Spanner Wrench 3212 To Counter-Hold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When loosening bolts use spanner wrench 3212 to counter-hold.

Fig 4: Removing Bolts & Front Sealing Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove front sealing flange.

Installing

Remove sealant from sealing flange groove and from sealing surfaces.

CAUTION: Make sure that no sealant residue enters the engine.

CAUTION: Wear safety glasses.

Fig 5: Using Rotating Plastic Brush To Remove Any Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using rotating plastic brush, remove any sealant residue from sealing flange, cylinder block and upper part of oil pan.
Clean sealing surfaces so they are completely free of any oil or grease.

Fig 6: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut tube nozzle at front marking (jet dia. approx. 2 mm).

Fig 7: Applying Bead Of Sealant To Clean Sealing Surface Of Sealing Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply bead of sealant as illustrated to clean sealing surface of sealing flange.

The groove - arrow - of sealing surface must be completely filled with sealant.
Sealant bead must stand 1.5 to 2.0 mm above sealing surface.

NOTE:

Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.
The front sealing flange must be installed within 5 minutes of being applied with sealant.

Fig 8: Inserting Assembly Device T40048/1 Onto Pull Sleeve T40048/2 And Sliding Sealing Flange Onto Pull Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert assembly device T40048/1 onto pull sleeve T40048/2 and slide sealing flange - 1 - onto pull sleeve.
Remove assembly device.

Fig 9: Placing Sealing Flange With Inserted Pull Sleeve T40048/2 Onto Crankshaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place sealing flange - 1 - with inserted pull sleeve T40048/2 onto crankshaft.

Fig 10: Removing Bolts & Front Sealing Flange

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten bolts - arrows - in a diagonal sequence and in steps.

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

Install vibration damper Installing .
Install ribbed belt Installing .
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.

Torque specifications

Component	Nm
Front sealing flange to cylinder block	9 ¹⁾
Ribbed belt pulley to coolant pump	20
¹⁾ Tighten diagonally in stages.