Sealing Flange, Belt Pulley Side

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Counter support 3415
Assembly tool T10053
Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Hand drill with plastic brush attachment
Flat scraper
Silicone sealant D 176 404 A2

Removing

-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Remove the toothed belt, refer to one of the following:

-- Loosen the crankshaft toothed belt gear. Secure the toothed belt gear using the 3415.

Fig 1: Identifying Counter-Hold 3415 On Crankshaft Toothed Belt Sprocket

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-- Remove the crankshaft toothed belt gear center bolt -1-, and gear -2-.

Fig 2: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

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-- Remove the diamond disc -3- from the toothed belt gear.

-- Drain the engine oil.

-- Remove the oil pan. Refer to OIL PAN .

-- Remove the sealing flange bolts.

-- Remove the sealing flange, and if necessary loosen by applying light strikes using a rubber hammer.

-- Drive out the seal with the sealing flange removed.

-- Remove any sealant residue from the cylinder block with a flat scraper.

-- Cover the seal with a clean cloth.

NOTE:

If the oil seal is to be replaced, drive out the old oil seal.

-- Remove any sealant residue from the sealing flange using a rotating plastic brush (wear safety glasses).

Fig 3: Identifying Rotating Plastic Brush

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-- Clean the sealing surfaces. They must be free of oil and grease.

Installing

-- Cover the sealing surface of seal using a clean cloth before applying the sealant bead.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 3 mm).

Fig 4: Identifying Silicone Sealing Compound Bead

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-- Apply a sealant bead of approximately 2 to 3 mm as shown -arrows- onto the clean sealing surface of the sealing flange.

NOTE:

Note the expiration date of the sealing compound.

The sealant bead must not be thicker than 2 to 3 mm or excess sealant could get into the oil pan and clog the oil intake pipe strainer.

Note the expiration date of the sealing compound.

The sealing flange must be installed within 5 minutes after application of silicon sealant.

To position the sealing flange with the seal installed, use the T10053/1.

After installing, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

-- Position the sealing flange immediately and lightly tighten all the bolts -arrows-.

Fig 5: Identifying Sealing Flange Bolts

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-- Tighten the sealing flange bolts in a diagonal sequence.

Tightening specification: 15 Nm.

-- Remove any excess sealant. There must be no sealant located on the crankshaft bearing end and the sealing surface of the seal.

-- Install the oil pan. Refer to OIL PAN .

-- Install a new seal for the crankshaft. Refer to CRANKSHAFT SEAL, BELT PULLEY SIDE .

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

Fig 6: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

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NOTE:

There must be no oil on the contact surfaces between the toothed belt gear, diamond disc and crankshaft.

Replace the center bolt and the diamond disc.

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

-- Install the toothed belt gear -2- with diamond disc -3- and tighten the bolt -1- hand tight.

Fig 7: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc

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-- Use the 3415 to tighten the crankshaft toothed belt gear bolt.

Fig 8: Identifying Counter-Hold 3415 On Crankshaft Toothed Belt Sprocket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the center bolt to 90 Nm and then an additional 90° (¹ /₄ turn). The additional turn can be done in steps.

The rest of the assembly is basically a reverse of the removal sequence.

Install the toothed belt and adjust the valve timing, refer to one of the following: