Volkswagen Golf Service & Repair Manual: Removing and installing sealing flange on pulley end

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Enginecrankshaft group, pistons / Cylinder block (pulley end) / Removing and installing sealing flange on pulley end

Special tools and workshop equipment required

Flat scraper

Sealant → Electronic Parts Catalogue

Removing

–	Remove noise insulation → General body repairs, exterior; Rep. gr.66.

–	Remove air conditioner compressor with refrigerant lines connected, and tie it up on the right side → Heating, air conditioning; Rep. gr.87.

–	Remove toothed belt → Chapter.

–	Detach crankshaft pulley -1--arrow-.

Risk of damage to engine caused by incorrect valve timing.Do not turn crankshaft out of TDC position.

Removing and installing sealing flange on pulley end

–	Unscrew bolts -1 … 8- and carefully remove sealing flange from the glued joint.

–	Drive out seal with sealing flange removed.

Installing

Installation is carried out in the reverse order; note the following:

The lubrication system can be soiled by sealant residue.

Cover open section of sump with clean clothes.

–	Remove sealant residue from sealing flange and sump (top section).

–	Remove any oil and grease from sealing surfaces.

Note

Removing and installing sealing flange on pulley end

Observe use-by-date of sealant.

–	Cut off nozzle on tube at front marking (diameter of nozzle approx. 2 mm).

Removing and installing sealing flange on pulley end

–	Slide gasket -1- onto dowel pins in cylinder block.

–	Apply a thin bead of sealant at the edge of the joint between the cylinder block and the sump -arrows-.

Removing and installing sealing flange on pulley end

–	Thinly coat lower sealing surface -arrow- of sealing flange with sealant.

Note

Install the sealing flange within 5 minutes after the sealant has been applied.

–	Carefully fit gasket sealing flange onto dowel pins on cylinder block.

–	Tighten bolts for sealing flange → Fig..

–	Install crankshaft oil seal on belt pulley end → Chapter.

Removing and installing sealing flange on pulley end

–	Fit crankshaft sprocket onto crankshaft.

The contact surface between vibration damper and crankshaft pulley must be free of oil and grease.

The machined surface -arrow- of crankshaft pulley must be positioned over the machined surface of the crankshaft journal.

–	Install toothed belt (adjust valve timing) → Anchor.

–	Install air conditioner compressor → Heating, air conditioning; Rep. gr.87.

–	Install noise insulation → General body repairs, exterior; Rep. gr.66.

Specified torques

→ Fig. „“Sealing flange at belt pulley end - Prescribed torque and tightening sequence”“

→ Heating, air conditioning; Rep. gr.87

Removing and installing sealing flange on pulley end

Renewing crankshaft oil seal - belt pulley end

Special tools and workshop equipment required Assembly tool -T10485- ...

Cylinder block, gearbox end

...

Other materials:

Front axle
Overview of fitting locations - front axle I - → Chapter „Subframe“ II - → Chapter „Suspension strut, upper suspension link“ III - → Chapter „Lower suspension link ...

Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003
– Apply handbrake. – Vehicles with automatic gearbox, move selector lever to position “P” or “N”. – Vehicles with manual gearbox, move gear lever to neutral position. ...

Assembly overview - front vehicle level senders
Note The front left/right vehicle level sender -G78/G289- is only available as a replacement part complete with coupling rod and upper and lower retaining plates. 1 - Suspension link 2 - Subframe 3&nbs ...