Volkswagen Workshop Service and Repair Manuals

Removing and installing sealing flange (belt pulley end)

Special tools and workshop equipment required

t	Counterhold tool -3415-

t	Assembly tool -T10053-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Hand drill with plastic brush

t	Silicone sealant -D 176 404 A2-

t	Flat scraper

Removing sealing flange: –  Remove poly V-belt → Chapter. –  Remove toothed belt:    Vehicles with split toothed belt guard → Chapter.    Vehicles without split toothed belt guard → Chapter. –  Turn crankshaft back slightly.

–  Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3415-. –  Drain engine oil. –  Remove sump → Chapter. –  Unscrew sealing flange (belt pulley end). –  Remove sealing flange; if necessary, loosen using light blows with a rubber headed hammer. –  Remove sealant residue from cylinder block with a flat scraper. –  Cover seal with a clean cloth.   Note If seal is to be renewed, drive out seal.

–  Remove residual sealant on sealing flange using a rotating plastic brush (wear eye protection). –  Clean sealing surfaces. They must be free of oil and grease. Installing sealing flange:

–  Cut off tube nozzle at forward marking (Ø of nozzle approx. 3 mm). –  Apply sealant bead of about 2…3 mm as shown -arrows- to clean sealing surface of sealing flange.   Note t  Before applying sealant bead, cover sealing ring with a clean cloth. t  The sealing compound bead must not be thicker that 2…3 mm. Otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer. t  Observe expiry date of sealing compound. t  The sealing flange must be installed within 5 minutes after applying the silicone sealant. t  When fitting sealing flange with oil seal installed use guide sleeve -T10053/1-. t  Sealing compound must dry for approx. 30 minutes after installation. Only then fill with engine oil.

–  Fit sealing flange immediately and lightly tighten all bolts -arrows-. –  Tighten sealing flange securing bolts diagonally and alternately. Specified torque: 15 Nm. –  Remove excess sealant. –  Install sump → Chapter. –  If necessary, install seal → Chapter.   Note t  Contact surface between pulley, diamond-coated washer and crankshaft must be free of oil. t  The centre bolt must be renewed. t  Thread and shoulder must be free of oil and grease.

–  Fit toothed belt pulley -2- with diamond-coated washer -3- and tighten bolt -1- hand-tight.

–  Lock toothed belt pulley using counterhold -3415-. –  Tighten new centre bolt to 90 Nm and turn 90° (1/4 turn) further (turning further can be done in several stages). Further assembly is basically the reverse of the dismantling sequence. Installing toothed belt and adjusting valve timing.    Vehicles with split toothed belt guard → Chapter.    Vehicles without split toothed belt guard → Chapter.