Sealing Flange, Belt Pulley Side

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items 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

• Silicone Sealant (D 176 404 A2)

• Flat Scraper

Removing

- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.

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

• With a divided toothed belt guard, refer to => [ Toothed Belt, with a Divided Toothed Belt Guard ] Toothed Belt, with a Divided Toothed Belt Guard.

• Without a divided toothed belt guard, refer to => [ Toothed Belt, without a Divided Toothed Belt Guard ] Toothed Belt, without a Divided Toothed Belt Guard.

- 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).






- Drain the engine oil.

- Remove the oil pan. Refer to => [ Oil Pan ] Service and Repair.

- 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.

• Remove the seal if replacing it.

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






- 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).






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

• 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 -.






- 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 ] Service and Repair.

- Install the seal, if necessary. Refer to => [ Crankshaft Seal, Belt Pulley Side ] Service and Repair.

• 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.






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






- 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:

• With a divided toothed belt guard, refer to => [ Toothed Belt, with a Divided Toothed Belt Guard ] Toothed Belt, with a Divided Toothed Belt Guard.

• Without a divided toothed belt guard, refer to => [ Toothed Belt, without a Divided Toothed Belt Guard ] Toothed Belt, without a Divided Toothed Belt Guard.