Front Sealing Flange

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

Special tools and workshop equipment required

Counter Support 3415
Assembly Tool T10053
Torque Wrench 5-50 Nm V.A.G 1331
Torque Wrench 40-200 Nm V.A.G 1332
Hand drill with plastic brush attachment
Protective eyewear
Sealant.

Removing

-- Remove ribbed belt. Refer to RIBBED BELT .

-- Toothed belt, removing. Refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW .

-- Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with the 3415.

Fig 1: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415

Courtesy of AUDI OF AMERICA, LLC

-- Remove the crankshaft-toothed belt sprocket center bolt -1- -2- and remove the toothed belt sprocket.

Fig 2: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

Courtesy of AUDI OF AMERICA, LLC

-- Remove diamond disc -3- from toothed belt gear.

-- Remove the bolts -1 through 10-.

Fig 3: Fastening Bolts In Specified Order

Courtesy of AUDI OF AMERICA, LLC

-- Pry off and remove front sealing flange.

-- Drive out the seal from the removed flange.

Installing

Tightening specifications, refer to FRONT SEALING FLANGE OVERVIEW

NOTE:

Place a rag over open part of oil pan.

-- Carefully remove any sealant residue from the cylinder block and oil pan.

WARNING:

Wear safety glasses.

-- Remove sealant residue from sealing flange for example with a rotating plastic brush.

Fig 4: Identifying Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

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

-- Cut tube nozzle at front marking (nozzle diameter: approximately 2 mm).

Fig 5: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of AUDI OF AMERICA, LLC

-- Apply a thin bead of sealant to the edge between cylinder block and oil pan -arrow-.

Fig 6: Applying Thin Bead Of Sealant To Edge Between Cylinder Block And Oil Pan

Courtesy of AUDI OF AMERICA, LLC

-- Apply a thin bead of sealant -arrow- to the clean sealing surface of the sealing flange, as shown in the illustration.

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

Courtesy of AUDI OF AMERICA, LLC

Thickness of sealant bead: 2 to 3 mm.

CAUTION:

Risk of plugging oil pump strainer with excess sealant.

Do not apply sealant bead thicker than indicated.

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 the lower sealing surface of the sealing flange with sealant -shaded area-.

Fig 8: Lightly Coating Lower Sealing Surface Of Sealing Flange With Sealant

Courtesy of AUDI OF AMERICA, LLC

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.

-- Tighten sealing flange bolts in 3 stages as follows:

Fig 9: Fastening Bolts In Specified Order

Courtesy of AUDI OF AMERICA, LLC

-- Install bolts -1 through 10- and tighten by hand.

-- Tighten bolts -1 through 6- in a diagonal sequence in stages.

-- Tighten bolts -7 through 10-.

-- Install the crankshaft seal -belt pulley side- INSTALLING .

-- Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-.

Fig 10: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil.

Do not oil the bolt for crankshaft toothed belt sprocket.

-- Use the 3415 to tighten crankshaft toothed belt gear.

Fig 11: Crankshaft Toothed Belt Sprocket, Removing And Installing

Courtesy of AUDI OF AMERICA, LLC

The rest of the installation is performed in reverse order of removal, noting the following:

How to install toothed belt and adjust valve timing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

-- Install vibration damper. Refer to VIBRATION DAMPER .

-- Install the ribbed belt. Refer to RIBBED BELT .