Front Engine Plate: Service and Repair

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items 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, refer to the following:

• Jetta from MY 11. Refer to => [ Ribbed Belt ] Service and Repair.

- Lock the crankshaft. Refer to => [ Crankshaft, Locking ] Procedures.

- Remove the vibration damper from the crankshaft.

- Remove the tensioner - 1 -.






- Remove the sealing flange bolts - 2 -.

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






- Use the trim removal wedge (3409) to support the screwdriver in order to prevent damage to the sealing flange of cylinder block.

The sealing flange is damaged while removing.

- Pry off the sealing flange completely.

• After removing the sealing flange, clean the trim removal wedge (3409) which is intended for the removal of the interior equipment parts.

Installing


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

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


Make sure that no sealant residue enters the engine.

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

• Do not additionally lubricate or grease the sealing lip of the sealing flange!

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

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






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.






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).






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

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






• Width of the sealant bead: 2.5 to 3.0 mm

• Height of the sealant bead above the sealing surface: approximately 1.0 mm

- Install the sealing flange using the oil seal guide sleeve (T03004) onto the crankshaft journal and press uniformly onto the cylinder block.






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

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• Remove locking pin (T40069) from the rear of the cylinder block and install the locking bolt.

Tightening Specifications






• 1 Always replace