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Home >> Volkswagen >> 2006 >> GTI 1.8 E, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (2.0L - Crankshaft, Cylinder Block - Engine Code(S): BPY) >> 13 Crankshaft, Cylinder Block >> Removal And Installation >> Sealing Flange, Belt Pulley Side

Sealing Flange, Belt Pulley Side

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required 

Removing 

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

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

-- Rotate the crankshaft back just a little.

-- Remove the crankshaft toothed belt gear. To do this, secure the toothed belt gear using the counter support 3415.

Fig 1: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415
GWWN13-0401Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Drain the engine oil.

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

-- Remove the sealing flange bolts.

-- Remove the sealing flange. If necessary use a rubber hammer and tap it gently.

-- Scrape off any sealant still on the cylinder block using a flat blade scraper.

-- Cover the seal with a clean cloth.

NOTE:

Remove the seal if replacing it.

-- Remove any sealant still on the sealing flange using a rotating plastic brush. Wear protective eye-wear.

Fig 2: Identifying Rotating Plastic Brush
GWWA17-0030Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Installing 

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 3 mm).

Fig 3: Applying Silicone Sealing Compound
GWWN17-0084Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

NOTE:

Cover the seal with a clean cloth before applying the sealant bead.

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

Note the expiration date of the sealant.

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

To position the sealing flange with the seal installed, use the guide sleeve 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 bolts -arrows-.

Fig 4: Identifying Sealing Flange Bolts
GWWN13-0786Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Tighten the sealing flange bolts in a diagonal sequence. Tightening specification: 15 Nm

-- Remove the excess sealant.

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

-- Install the seal, if necessary. Refer to CRANKSHAFT SEAL, BELT PULLEY SIDE .

NOTE:

The contact surface between the toothed belt gear, diamond disc and crankshaft must be free of oil.

The toothed belt gear bolt must be replaced.

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

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

Fig 5: Identifying Center Bolt, Crankshaft Toothed Belt Gear & Diamond Disc
GWWA13-10316Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Secure the toothed belt gear using the counter support 3415.

Fig 6: Counter-Holding Crankshaft Toothed Belt Sprocket With 3415
GWWN13-0401Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Tighten the new toothed belt gear bolt to 90 Nm + an additional 90° (1/4), (the additional turn may occur in several stages).

Further installation is in the reverse order of removal.

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

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