Front sealing flange, removing and installing

Fig 1: Identifying Special Tools - Front Sealing Flange, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Counter-holder tool 3415
Assembly tool T10053
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332

Hand drill with plastic brush attachment
Protective glasses
Sealant

Removing

Remove ribbed belt → Ribbed belt, removing and installing .
Toothed belt, removing → Toothed belt drive, overview .

Fig 2: Securing Toothed Belt Gear Using Counter Support 3415

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen toothed belt crankshaft sprocket by holding sprocket with Counter Support 3415.

Fig 3: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove toothed belt crankshaft sprocket center bolt - 1 - and remove sprocket - 2 - and diamond disc - 3 -.

Fig 4: Locating Bolts In Specified Order

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Remove bolts - 1 to 10 -.
Pry off and remove front sealing flange.
Drive out seal from removed flange.

Installing

NOTE:

Place a rag over open part of oil pan.

Carefully remove any sealant residue from cylinder block and oil pan.

CAUTION: Wear safety glasses.

Fig 5: Removing Sealant Remains On Sealing Flange With Rotating Plastic Brush

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove sealant residue from sealing flange e.g. with a rotating plastic brush.
Clean sealing surfaces, they must be free of oil and grease.

Fig 6: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Fig 7: Applying Thin Bead Of Sealant To Edge Between Cylinder Block And Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply a thin bead of sealant to edge between cylinder block and oil pan - arrow -.

Fig 8: Identifying Silicone Sealant Bead

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply a thin bead of sealant - arrow - to clean sealing surface of sealing flange, as shown in the illustration.

Thickness of sealant bead: 2 to 3 mm.

NOTE:

The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

Fig 9: Lightly Coating Lower Sealing Surface Of Sealing Flange With Sealant

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lightly coat lower sealing surface of sealing flange with sealant - shaded area -.

NOTE:

The sealing flange must be installed within 5 minutes of being applied with sealant.

Carefully slide sealing flange onto reamed bolt at cylinder block.

NOTE:

To install the sealing flange with installed seal, use the guide sleeve T10053/1.

Fig 10: Locating Bolts In Specified Order

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten bolts in specified order:
Tighten bolts - 1 to 6 -.
Tighten bolts - 7 to 10 -.
Install crankshaft seal (belt pulley side) Installing .

Replace center bolt for toothed belt sprocket.

NOTE:

There must be no oil on the contact surface between the toothed belt sprocket and crankshaft.
Do not oil bolt for crankshaft toothed belt sprocket.

Fig 11: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.

Fig 12: Securing Toothed Belt Gear Using Counter Support 3415

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hold toothed belt crankshaft sprocket with Counter Support 3415 and tighten.

The rest of installation is in reverse order of removal, note the following:

How to install toothed belt and adjust valve timing → Toothed belt, removing and installing

Install crankshaft belt pulley → Crankshaft belt pulley, removing and installing
Install ribbed belt → Ribbed belt, removing and installing .
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 13: Identifying Lock Carrier With Attachments

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component		Nm
Sealing flange to cylinder block		15
Toothed belt sprocket to crankshaft		90 + 90 ° ¹⁾²⁾
Torque support stop		28
¹⁾ Replace bolt ²⁾ 90 °Corresponds to a 1/4 turn

NOTE:

The threads and shoulder must be free of oil and grease.