Sealing Flange & Flywheel/Drive Plate, Removing and Installing
Sealing flange and flywheel/drive plate, removing and installing
Note:
For clutch repairs:
1- 90 Nm (66 ft. lbs.) + 1/4 turn (90°) further
- Replace
^ To loosen and tighten: counterhold with 3099
2- Crankshaft toothed belt sprocket
3- 15 Nm (11 ft. lbs.)
4- oil seal
^ Replacing. Refer to Sealing flange and flywheel/drive plate, removing and installing.
5- Sealing flange
6- Engine block
^ Crankshaft, removing and installing.
^ Pistons and conrods: Disassembly and assembly
7- 60 Nm (44 ft. lbs.) + 1/4 turn (90°) further
- Replace
8- Flywheel/drive plate
^ Flywheel: remove and install with 3067 counterhold
^ Drive plate: removing and installing.
9- Intermediate plate
^ Must be located on dowel sleeves
- Do not damage/bend when assembling
10- Sealing flange with oil seal
- Only replace complete
- Lightly oil lip on seal
- Install new sealing flange with guide sleeve (guide sleeve not removed from gasket before removing)
Crankshaft oil seal (pulley end), replacing
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
^ 2080 A sleeve
^ 3203 Oil seal extractor
^ 3266 Press fit sleeve
^ 3415 Counter support
^ VAG 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG 1332 Torque wrench40 to 200 Nm (30 to 148 ft. lbs.)
Crankshaft oil seal (pulley end), removing
- Remove ribbed belt.
- Remove toothed belt.
- Remove crankshaft toothed belt sprocket by counterholding sprocket with 3415.
- To guide seal extractor, screw center bolt into crankshaft onto stop by hand.
- Unscrew inner part of oil seal extractor 3203 nine turns (approx. 20 mm) out of the outer part and lock with knurled screw.
- Lubricate threaded head of oil seal extractor 3203, place it in position and exerting firm pressure screw it as far as possible into oil seal.
- Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out.
Crankshaft oil seal (pulley end), installing
- Lightly oil sealing lip of oil seal.
- Install guide sleeve from 2080 A onto crankshaft journal.
- Slide oil seal over guide sleeve.
- Press in seal with press sleeve from 3266, using old center bolt for crankshaft toothed belt sprocket:
- Press in sleeve up to stop.
- Install crankshaft toothed belt sprocket and hold with 3415 counter-hold.
- Install toothed belt and adjust timing.
- Install ribbed belt.
Sealing flange (front), removing and installing
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
^ 2080 A sleeve
^ 3415 Counter support
^ VAG 1331 Torque wrench
5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG 1332 Torque wrench
40 to 200 Nm (30 to 148 ft. lbs.)
^ Hand drill w/ plastic brush insert
^ D 176404 A2 Silicone sealant
^ Flat scraper
Sealing flange, removing
- Remove ribbed belt.
- Remove toothed belt.
- Remove crankshaft toothed belt sprocket by counterholding sprocket with 3415.
- Remove oil pan.
- Unbolt front sealing flange.
- Remove sealing flange.
^ Release using light blows from rubber hammer, if necessary
- Remove sealant remnants on engine block with flat scraper.
- Remove sealant remains on sealing flange with a rotating plastic brush (wear protective goggles).
- Clean sealing surfaces, they must be oil and grease free.
Sealing flange, installing
Note:
Install the sealing flange within 5 minutes of applying the silicone sealant.
- Cut-off tube nozzle at forward mark (nozzle approx. 3 mm 0)
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealing compound bead must be:
^ Thickness of sealant bead -arrows-: 2 to 3 mm
Note:
The sealing compound bead must not be thicker otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer
- Apply silicone sealant bead (as shown) to the clean sealing surface of the sealing flange.
- Immediately install sealing flange and lightly tighten all bolts.
Note:
Use guide sleeve from 2080A to install sealing flange with oil seal already installed.
- Tighten sealing flange mounting bolts using alternate sequence.
- Tightening torque: 15 Nm (11 ft. lbs.)
- Install oil pan.
Note:
After installing, allow sealant to dry for approx. 30 minutes before filling with engine oil.
- Install toothed belt and check timing.
- Install ribbed belt.
Drive plate, removing and installing
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
^ VW 558 Counterhold tool
^ M8 x 45 Hex bolt and two M10 hex nuts
^ Depth gauge
Drive plate, loosening and tightening
- Attach WV 558 counter-hold tool to the drive plate with an M8 x 45 hex bolt. Place two M10 hex nuts between counterhold and drive plate.
Position of counterhold tool:
A- To loosen
B- To tighten
Installing drive plate
- Locate drive plate and backing plate with recesses -1-.
- Install new bolts -3- and tighten.
^ 30 Nm (22 ft. lbs.)
- Check dimension -a- at three points and calculate average.
^ Specification: 19.5 to 21.1 mm
Note:
Because of the hole through the drive plate it is measured on the milled surface of the engine block
If specification not obtained:
- Remove drive plate again and install shim -2-.
- Again tighten bolts -3-
^ 30 Nm (22 ft. lbs.)
- Tighten bolts to 60 Nm (44 ft. lbs.) and turn 90° (1/4 turn) further (can be done in several stages).