Front Sealing Flange, Removing and Installing Audi TT 8N

Special tools, testers and auxiliary items required

1. Sealant

Removing

1. Engine installed

1. Remove screw -1- and remove cover over coolant expansion tank (arrow).

Note. Before removing the poly V-belt, mark the direction of rotation on the belt with chalk or a felt-tipped pen. A reversed rotation direction can cause the belt to be damaged in operation.

1. To release tension of poly V-belt, screw an M8 x 40 bolt (arrow) into bore on tensioning element.
2. Remove poly V-belt from Generator pulley.

1. Remove fasteners -1...3- and center sound insulation.

1. Remove right sound insulation (arrows).
2. Remove poly V-belt from pulley for vibration damper.

1. Remove bolt from vibration damper using counter-hold T10069.

Scheme 82

1. Remove bolts -1...11-.
2. Pry off and remove front sealing flange.
3. Drive seal out of removed flange.

Installing

Installation is performed in the reverse order of removal. Note the following

Note. Place a rag over the open portion of the oil sump

Scheme 83

1. Remove residual sealant from sealing flange with a rotating plastic brush.
2. Clean sealing surfaces. They must be free of oil and grease.

Scheme 84

1. Cut off nozzle on tube of sealant at front mark (diameter of nozzle approx. 3 mm).

Scheme 85

1. Apply a thin bead of sealant to edge between cylinder block and oil sump (arrow).

Scheme 86

1. Lightly coat lower sealing surface of sealing flange with sealant (shaded area).

Scheme 87

1. Apply a thin bead of sealant (arrow) to clean sealing surface of sealing flange, as shown in illustration.

1. Thickness of sealant bead (arrow): 2 to 3 mm

Note. The sealant bead may not be thicker than 2 to 3 mm. If thicker, the excess sealant could enter the oil sump and clog the oil intake tube. The sealing flange must be installed within 5 minutes of applying the sealant.

1. Carefully push sealing flange onto locating pins on cylinder block.

Note. To install the sealing flange with an installed seal, use guide sleeveT10053/1.

1. Fasten bolts in specified order
2. Fasten bolts -1...6-.
3. Fasten bolts -7...16-.
4. Install crankshaft seal for vibration damper side. Refer to «Crankshaft oil seal - vibration damper end, replacing»(ref-276269-S24757855402008010300000) .

1. Install vibration damper with new bolt. Refer to «Vibration damper, removing and installing»(ref-276269-S29111113012008010300000) .
2. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(ref-276269-S17467268642008010300000) ..

Tightening torque

Scheme 88

Note. To perform assembly work, secure engine to engine stand. Refer to Engine, securing to engine stand .

1 - 60 Nm + 90° (1/4 turn) further

1. Replace

2 - Dual-mass flywheel

1. Removing and installing. Refer to «Dual mass flywheel, removing and installing»(ref-276269-S32858030262008010300000)

3 - Seal

1. Replace. Refer to «Crankshaft oil seal - timing chain end, replacing»(ref-276269-S37132612532008010300000)

4 - 23 Nm

1. Tightening order. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(ref-276269-S28334020092008010300000)

5 - Thermostat housing

1. Removing and installing. Refer to «Thermostat housing, removing and installing»(ref-276269-S29370771572008010300000)

6 - 10 Nm

7 - Secondary air hose retainer

8 - Gasket

1. Replace

9 - Seal

1. 2 pieces
2. For Valve -1- for camshaft adjustment -N205- and Camshaft adjustment valve 1 (exhaust) -N318
3. Removing and installing. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(ref-276269-S31378565982008010300000)

10 - 10 Nm

11 - Camshaft position sensor

1. 2 pieces
2. Mark electrical connector before disconnecting

12 - O-ring

1. 2 pieces
2. Replace

13 - Upper timing chain cover

1. Coat sealing surfaces with sealant when installing

14 - Guide sleeve

1. 2 pieces

15 - Gasket

1. Replace

16 - O-ring

1. Replace

17 - Seal

1. Replace

18 - Chain tensioner for camshaft timing chain

1. Fasten to 40 Nm

19 - 10 Nm

1. Tightening order. Refer to «Drive chain for valve gear and camshaft timing chain, removing and installing»(ref-276269-S28334020092008010300000)

20 - Cylinder head gasket

1. Clean holes and fill with sealing compound. Refer to «Camshaft timing chain, removing from camshafts»(ref-276269-S22252894662008010300000)

21 - Guide pin

22 - Lower timing chain cover

1. Coat sealing surfaces with sealant.

23 - 10 Nm

1. Fasten diagonally in steps