Pulley shroud is held by two short 6mm long bolts.
There are special 6mm long bolts for holding the pulley shroud. Do not use longer ones. Use two 6mm washers bevelled edges outwards and hand tighten until snug. There are 2 typed of pulley shrouds depending on whether you have the late larger oil pump or the earlier smaller one.
Pulley seal.
Take the pulley seal from the gasket kit. Get your oil slinger washer.
Oil slinger and pulley seal
You will need the special tool to install this seal. It is available from the main parts dealers and is essential to fit the seal correctly. This is because the seal is indented slightly into the third piece and this tool does this. It is a Porsche tool and not a VW tool.
Clean the sealing surface of the case and the oil slinger with WD 40 and wipe off with kitchen paper.
Coat the sealing surface with a little white grease and also the outer surface of the bearing.
Put the oil slinger in place first and then put the seal onto the seal installer.
Seal Installer in use.
First use a spanner on the hex nut nut on the end of the seal installer to screw the tool into the cranshaft. next use a spanner as illustrated above to gently tighten the tool which pushes the seal into place. Dont overtighten it!
Back off the installer and remove it. You will now see that the seal is recessed into the third piece by about 1/16".
If you have an early engine it may well have a different arrangement. Take a look at the next two photographs. The first shows that the third piece has 5 studs around the end of the crank and no obvious place for the seal. The second photo shows that the seal is installed in a special cover that fits on the 5 studs and is held in place by nuts and washers. Your seal installer will not work for this early arrangement and the seal needs to be pressed into place using a hydraulic press with the correct size plate to press the seal.
Five studs clearly visible around the end of the crank
Seal installed on end plate and coated with flange sealant ready for assembly
Take the paper seal from your gasket set. Make sure it fits over the studs. Coat the gasket surface with a little flange sealant on the side that mates with the third piece. Do the same on the cover plate.
Make sure the PULLEY KEY is in place (see later)
Place the cover over the studs with the gasket in place and pop on the washers. Evenly tighten the nuts
and torque to 10-12 ft lbs. Clean off any excess flange sealant.
There is a porsche tool for installing the seal - I have never seen one!
Installing pulley.
Turn the engine over until the slot for the pulley key is vertical. take the pulley key and gently tap into place.
Take the pulley and lubricate the pulley sealing surface with some stp/oil mix. tap on with palm of hand or rubber hammer. Take the pulley nut and washer and pop on. Get a 30mm socket and start to tighten. (you will need your flywheel lock in place) Tighten it firmly but not to tight as you may want to remove it.
Oil cooler.
Next we will install the oil cooler. I would always recommend fitting a new oil cooler. The ones available now have 8mm studs and thee earlier engines only had 6mm holes so the 2 holes will need to be drilled out to 8mm.
Carefully remove the blanking pieces from the base of the oil cooler or you won`t get any cooling!
Take the 2 seals from your gasket set and lubricate both sides with stp/oil mix and rhen place onto the holes as in the photo below. Note that the stud is 6mm, I believe you can get a step stud to replace it with to make it 8mm. (thanks to Gary Koehler for info).
Seals in place ready for oil cooler to be fitted.
Put a little stp/oil mix on the bottom of the oil cooler where the seals meet it.
I like to use 13mm captive nuts for bolting on the oil cooler but if you want originality use some red loctite to ensure they do not come loose. Pop the cooler into place and use two 13mm nuts and small washers and hand tighten them. Use a 6mm washer and 10mm nut on the stud. Again I prefer a captive nut but if you use the original then use red loctite. Some people double nut this stud to ensure it does not loosen.
Tighten the 3 nuts evenly alternating between nuts so that the oil cooler does not twist. Do not over tighten or you can crack the oil cooler stand - a disaster!
Cooler in place with 10mm nylock captive nut.
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