Sealing Flange, Belt Pulley Side: Installing

WARNING: This page is about a different car, the 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: To prevent injuries from shavings, wear protective goggles and protective clothing.

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

CAUTION: Make sure that no sealant residue enters the engine.

-- Clean sealing surface of cylinder block and crankshaft journals; they must be free of oil and grease.

NOTE:

Do not additionally oil or grease sealing lip of sealing flange!

The following work steps must be followed so that the sealing lip of sealing flange does not roll itself up when installing.

-- Widen sealing lip of new sealing flange as shown using Oil Seal Guide Sleeve T03004.

Fig 1: Identifying Sealing Lip Of New Sealing Flange Widened Using Assembly Sleeve T03004

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Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The surface -A- is the outer side.

-- After a short while, remove the Oil Seal Guide Sleeve T03004 and turn it 180° rotated in the seal.

Fig 2: Identifying Sliding Assembly Sleeve T03004 Into Sealing Ring

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Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Fig 3: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE: The sealing flange for crankshaft -belt pulley side- must be installed within 5 minutes after application of sealant.

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

Fig 4: Applying Sealant Bead Into Groove Of Sealing Flange

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Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Sealant bead width: 2.5 to 3.0 mm
Seal bead height over the sealing surface: approximately 1.0 mm

-- Place the sealing flange on the crankshaft bearing using the Oil Seal Guide Sleeve T03004 and then press it evenly onto the cylinder block.

Fig 5: Identifying Sealing Flange Inserted Using Assembly Sleeve T03004 On Crankshaft Journals And Pressed Uniformly On Cylinder Block

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Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolt -A- evenly and in a diagonal sequence.

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

Remove the Crankshaft Locking Pin T40069 from the back of the cylinder block and install the bolt.