Sealing Flange, Removing And Installing, Belt Pulley Side

WARNING: This page is about a different car, the 2024 Audi RS 3. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Hose Clip Pliers :VAS 6340

Fig 1: Hose Clip Pliers VAS6340
Courtesy of AUDI OF AMERICA, LLC
Oil Seal Guide Sleeve :T03004

Fig 2: Identifying Assembly Sleeve T03004
Courtesy of AUDI OF AMERICA, LLC
Cleaning set for sealing surfaces :VAS 294 019

Courtesy of AUDI OF AMERICA, LLC
Protective Eyewear
Sealant. Refer to the => Parts Information.

Procedure

-- Remove the vibration damper. Refer to VIBRATION DAMPER, REMOVING AND INSTALLING .

-- If installed: loosen the hose clamp -2- and remove the air duct hose.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1 and 3-.

-- Loosen the hose clamps -arrows- and remove the air duct pipe.

-- Remove the bolts -arrow-.

Fig 3: Ribbed Belt Pulley Side Sealing Flange

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the sealing flange from the bond.

Replace the sealing flange after removal.

CAUTION:

Risk of contaminating the lubrication system with sealant residue.

- Cover open engine components.

Fig 4: Cleaning Sealing Surfaces

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of injuring the eyes from sealant residue.

- Wear protective eyewear.

-- Clean the sealing surfaces with the corresponding brush from the cleaning set for the sealing surfaces :VAS 294 019 .

Brush :VAS 294 019/1 for gray cast-iron surfaces
Brush :VAS 294 019/2 for aluminum surfaces
Brush :VAS 294 019/3 for painted surfaces

-- Clean any oil and grease off of the sealing surfaces and crankshaft journal.

Do not apply any additional oil or grease to the sealing lip of the seal in the sealing flange.

Fig 5: Widening Shaft Seal Sealing Lip With T03004

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of leaks due to incorrect handling.

The sealing lip of seal can be folded over if installed incorrectly.

- Install the seal using the method described.

-- Widen the sealing lip of the seal in the sealing flange as shown using the Oil Seal Guide Sleeve :T03004 .

Small diameter to the seal.

-- After five minutes remove the Oil Seal Guide Sleeve :T03004 and install it upside down into the shaft seal.

Fig 6: Widening Shaft Seal Sealing Lip With T03004

Courtesy of AUDI OF AMERICA, LLC

Larger diameter to the seal.
The Oil Seal Guide Sleeve :T03004 must be at the dimension -a- on the inside of the sealing flange.
Dimension -a- = approximately 3 mm.

Be sure to check the expiration date of the sealant.

Fig 7: Cut Tube Nozzle At Front Marking
Courtesy of AUDI OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

There is a risk that the lubrication system could be blocked by excess sealant.

- Do not apply sealant bead thicker than indicated.

-- Apply the sealant beads -1 and 2- to the clean sealing surface on the sealing flange.

Sealant bead thickness: 3 mm.
The sealing flange must be installed within five minutes of applying the sealant.

-- Carefully mount the sealing flange using the Oil Seal Guide Sleeve :T03004 on the crankshaft journal while pressing on the cylinder block at the same time and paying attention to the left and right side of the centering bushing.

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the sealing flange.

-- Install the vibration damper. Refer to VIBRATION DAMPER, REMOVING AND INSTALLING .

Tightening Specifications

Refer to Figure
Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS
Refer to OVERVIEW - CHARGE AIR SYSTEM .