Sealing Flange, Belt Pulley Side

Special tools and workshop equipment required 

• Trim Removal Wedge 3409
• Oil Seal Guide Sleeve T03004
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
• Silicone Sealant D 174 003 A2

Removing 

-- Remove the Air Conditioning (A/C) compressor ribbed belt. Refer to RIBBED BELT .

-- Lock the crankshaft. Refer to CRANKSHAFT, LOCKING .

-- Remove the vibration damper.

-- Remove the belt tensioner -1-.

Fig 1: Identifying Tensioning Element & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -2-.

-- Beginning at the alignment bushings -arrows-, pry off the sealing flange -1- using a suitable screwdriver -A-.

Fig 2: Pressing Off Sealing Flange Using Suitable Screwdriver

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Use the trim removal wedge 3409 to support the screwdriver in order to prevent damage to the sealing surface on the cylinder block.

The sealing flange is damaged while removing.

-- Pry off the sealing flange completely.

Installing 

-- Remove the remainder of the sealant from the cylinder block, using a rotating plastic brush, for example.

-- Clean the sealing surfaces on the cylinder block and crankshaft journal. They must be free of oil and grease.

-- Widen the sealing lip of the new sealing flange as shown using the oil seal guide sleeve T03004.

Fig 3: Widening Sealing Lip Of New Sealing Flange Using Assembly Sleeve T03004

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The surface -A- is the outer side.

-- After a short time, remove the oil seal guide sleeve T03004 and slide it rotated 180° into the seal.

Fig 4: Removing Assembly Sleeve T03004 And Sliding It Into Sealing Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

the oil seal guide sleeve T03004 must stand out approximately 3 mm on the inner side -B-. The surface -A- is the outer side. The surface -B- is the inner side (sealing surface).

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).

Fig 5: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Apply the sealant bead -A- as shown into the groove in the sealing flange.

Fig 6: Applying Sealant Bead Into Groove Of Sealing Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Width of sealant bead: 2.5 to 3.0 mm
• Height of sealant bead above the sealing surface: approximately 1.0 mm

-- Insert the sealing flange using the oil seal guide sleeve T03004 on the crankshaft journal and press the sealing flange uniformly onto the cylinder block.

Fig 7: Inserting Sealing Flange Using Assembly Sleeve T03004 On Crankshaft Journals

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolts -A- uniformly in a diagonal sequence.

The rest of the installation follows the reverse of the removal procedures. Note the following:

• Remove the locking pin T40069 from the cylinder block and install the plug.

Tightening Specifications