Sealing Flange, Belt Pulley Side

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 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) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Hand Drill with Plastic Brush Attachment
Protective Eyewear
Flat Scraper
Silicone Sealant D 176 404 A

Removing

-- Remove the toothed belt. Refer to TOOTHED BELT .

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the oil pan, refer to one of the following:

Engine code CBEA, refer to OIL PUMP, PAN AND BALANCE SHAFT MODULE OVERVIEW .

Engine code CJAA, refer to OIL PUMP AND OIL PAN OVERVIEW .

-- Remove the sealing flange bolts.

-- Remove the sealing flange. If necessary, loosen it by tapping it lightly with a rubber mallet.

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

WARNING:

Wear safety glasses.

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

Fig 2: Identifying Rotating Plastic Brush

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Installing

NOTE:

Note the expiration date of the silicone sealant D 176 404 A.

The sealing flange must be installed within 5 minutes after applying the silicone sealant D 176 404 A.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The sealant bead must not be thicker than 2 to 3 mm.

The extra sealant will get into the oil pan and can clog up the intake line for the oil pump.

Do not let the sealant drip onto the sealing surface of the crankshaft seal.

Before applying the bead of sealant, cover the sealing surface on the seal with a clean cloth

-- Apply a bead of silicone sealant to the surface of the sealing flange as illustrated.

Fig 4: Identifying Silicone Sealant Bead Applied To Clean Sealing Surface Of Sealing Flange

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the sealing flange immediately and tighten all bolts lightly.

NOTE:

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

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

Tightening specifications, see -item 7- in the SEALING FLANGE AND FLYWHEEL OVERVIEW .

-- Install the crankshaft toothed belt gear:

Tightening specification, see -item 2- in the TOOTHED BELT OVERVIEW .

-- Install the oil pan, refer to one of the following:

Engine code CBEA, refer to OIL PUMP, PAN AND BALANCE SHAFT MODULE OVERVIEW .

Engine code CJAA, refer to OIL PUMP AND OIL PAN OVERVIEW .

NOTE:

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

-- Install and tension the toothed belt. Refer to TOOTHED BELT .