Volkswagen Workshop Service and Repair Manuals

Removing and installing sealing flange - pulley end

Special tools and workshop equipment required

t	Counter-hold tool -3415-

t	Assembly tool -T10053-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

Not illustrated: t  Silicone sealant -D 176 404 A- t  Hand-held drill with plastic brush attachment t  Flat scraper t  Eye protection Removing –  Remove toothed belt → Chapter.

–  Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counter-hold tool -3415-. –  Drain engine oil. –  Remove sump → Chapter. –  Pull off front sealing flange. –  Remove sealing flange; if necessary, loosen by applying light blows with a rubber-headed hammer. –  Remove sealant residue from cylinder block using a flat scraper.

–  Remove residual sealant from sealing flange using a plastic rotary brush (wear eye protection). –  Clean sealing surfaces. They must be free of oil and grease. Installing   Note t  Observe expiry date of the sealant. t  Install sealing flange within 5 minutes of applying the silicone sealant.

–  Cut off tube nozzle at forward marking (approx. 3 mm nozzle Ø).   Note t  Sealant bead must not be wider than 2...3 mm, because otherwise excess sealant can enter sump and clog strainer in oil pump suction pipe as well as drip onto crankshaft oil seal. t  Before applying sealant bead, cover oil seal sealing surface with a clean cloth.

–  Apply silicone sealant bead as shown to the clean sealing surface of sealing flange. –  Install sealing flange immediately and tighten all bolts lightly.   Note When fitting sealing flange with oil seal installed, use guide sleeve -T10053/1-. –  Tighten securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence. –  Install sump → Chapter.   Note After fitting, allow sealant to dry for approx. 30 minutes. Only then fill with engine oil.

Install crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counter-hold tool -3415-. Tighten new centre bolt to 120 Nm and then 1/4 turn (90°) further (turning further can be done in several stages).   Note Thread and shoulder must be free of oil and grease. Installing toothed belt and adjusting valve timing → Chapter.