Sealing Flange, Belt Pulley Side, Removing And Installing

Special tools and workshop equipment required 

• Wrench - Pin Type3212
• Hand drill with plastic brush attachment
• Protective eyewear
• Sealant.

Removal

Fig 1: Identifying Bolt -1- And Coolant Hose -Arrow-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the coolant thermostat and connection, refer to CONNECTING PIECE WITH COOLANT THERMOSTAT, REMOVING AND INSTALLING .

-- Remove the vibration damper with the ribbed belt pulley, refer to VIBRATION DAMPER WITH RIBBED BELT PULLEY, REMOVING AND INSTALLING .

-- Remove the bolt -1-.

-- Tilt the toothed belt guard forward -arrows- and disengage the pins on the underside of the guard.

Fig 2: Identifying Toothed Belt Guard

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- for the coolant pump ribbed belt pulley using a Wrench - Pin Type3212 to counterhold.

Fig 3: Identifying Spanner Wrench 3212 And Bolts -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolt -1- and nut -2-.

Fig 4: Identifying Bolt -1- And Nut -2-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the right coolant pipe from the cylinder block and move it to the side.

-- Pry the cover off the ribbed belt idler roller.

Fig 5: Identifying Bolt -Arrow- And Idler Pulley

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolt -arrow- and remove the idler roller form the pulley side sealing flange.

-- Remove the bolts.

Fig 6: Identifying Removal Of Front Sealing Flange Sequence -- At Right -Arrows 1- Then At Left -Arrows 2-

Courtesy of AUDI OF AMERICA, LLC

-- First remove the right pulley side sealing flange -arrows 1- and then the left one -arrows 2-.

-- Remove the crankshaft seal on the removed sealing flange.

Installation

• Tightening specifications, refer to RIBBED BELT DRIVE OVERVIEW , SEAL AND SEALING FLANGE, PULLEY SIDE OVERVIEW .

-- Remove any old sealant from the grooves on the sealing flange as well as from the sealing surfaces.

Fig 7: Cleaning Remaining Sealant With Rotating Plastic Brush

Courtesy of AUDI OF AMERICA, LLC

-- Remove sealant residue on the sealing flange and the cylinder block and the upper part of the oil pan, for example using a rotating plastic brush.

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

NOTE:

Note the expiration date of the sealing compound.

Fig 8: Cut Tube Nozzle At Front Marking

Courtesy of AUDI OF AMERICA, LLC

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

-- Install the seals -2- and -4- and o-rings -1- and -3-.

Fig 9: Identifying Seals -2 & 4-, O-rings -1 & 3- And Sealant Bead

Courtesy of AUDI OF AMERICA, LLC

-- Apply sealant bead -arrow- to clean sealing flange pulley side sealing surface as shown in illustration.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

-- Tighten pulley side sealing flange bolts, refer to Figure.

Fig 10: Identifying Sealing Flange -Arrow- Bolts -- Tighten Diagonally

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

-- Install the pulley-side crankshaft shaft seal. Refer to CRANKSHAFT SHAFT SEAL, BELT PULLEY SIDE, REPLACING .

-- Install right coolant pipe, refer to COOLANT PIPES OVERVIEW .

-- Install the coolant pump ribbed belt pulley. Refer to COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW .

-- Install the vibration damper with ribbed belt pulley, refer to VIBRATION DAMPER WITH RIBBED BELT PULLEY, REMOVING AND INSTALLING .

-- Install the coolant thermostat and connection. Refer to CONNECTING PIECE WITH COOLANT THERMOSTAT, REMOVING AND INSTALLING .