Installing Front Crankcase Cover

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Installing stoppers in cylinder block

1. 2.1  Cut outer diameter of the three commercially available washers to slightly 7.7 mm. 
2. 2.2  Insert stoppers -2-  and washers -1-  using > V.A.G 1765C - pop rivet nut pliers  . The correct installation depth dimension -a-  = 2.4 mm  is set over the washers.
3. 2.3  Remove washers.

Information 

Do not use sharp-edged tools to clean the sealing faces.

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Inside of crankcase cover

1. 3.1  Remove crankshaft sealing ring.
   • Removing and installing crankshaft sealing ring  , Refer to the appropriate service information.
2. 3.2  Clean sealing faces with primer Loctite 7515. 
3. 3.3  O-rings -1-  replace
4. 3.4  Apply liquid sealant Loctite 5970-BM -2-  on the crankcase cover.

Fig 1: Crankcase Cover Screws Tightening Sequence

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Crankcase cover

1. 4.1  Position front crankcase cover. -18- 
2. 4.2  Fit screws on crankcase cover and tighten in the sequence. -1 to 17- 
   • Initial tightening 3 Nm (2 ftlb.) 

     Tighten screws on crankcase cover in the sequence. -1 to 11- 

   • Final tightening + 90° 

     Tighten screws securing crankcase cover to oil guide housing in the sequence. -12 to 17- 

   • Final tightening 9 Nm 

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Guide tube for oil dipstick

1. 5.1  Fit guide tube for oil dipstick -2-  into the crankcase cover.
2. 5.2  Fit and tighten screw on guide tube for oil dipstick. -1- 
   • Tightening torque 9 Nm (6.5 ftlb.) 

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Change-over valve holder

1. 6.1  Fit and tighten screws on holder. -1- 
   • Tightening torque 9 Nm (6.5 ftlb.) 

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Air-conditioning compressor bracket

1. 7.1  Replace screws on air-conditioning compressor bracket.
2. 7.2  Position air-conditioning compressor bracket. -5- 
3. 7.3  Fit and tighten new screws securing air-conditioning compressor bracket. -4- 
   • Initial tightening 8 Nm (6 ftlb.) 
4. 7.4  Install tensioning roller. -3- 
   1. 7.4.1  Position tensioning roller. -3- 
   2. 7.4.2  Fit screw on tensioning roller -2-  , but do not tighten yet.