Crankshaft Seal Retainer: Service and Repair
Crankshaft Sealing Flange, Flywheel Side
Special tools, testers and auxiliary items required
• Assembly tool (T10134)
• Torque Wrench (V.A.G 1331)
• SW 24 socket (V.A.G 1332/11)
• Caliper gauge
• Three hex bolts M6 x 35 mm
• Two hex bolts M7 x 35 mm
Sealing Flange with Sensor Wheel, Removing
- Remove the transmission:
• Manual transmission
• DSG transmission
- Remove flywheel --> [ 5 Flywheel ] Service and Repair.
- Remove intermediate plate --> [ 6 Intermediate Plate ] Service and Repair.
- Rotate crankshaft to TDC cylinder 1 as illustrated.
- Remove oil pan --> [ Oil Pan ] Service and Repair.
• To improve clarity, the work procedures will be shown with the engine removed.
• The work procedures are the same with the engine installed and removed.
- Remove the engine speed sensor. Refer to --> [ Engine Speed Sensor ] Service and Repair.
- Remove sealing flange bolts.
• The sealing flange and sensor wheel are pressed off the crankshaft with three bolts M6 x 35 mm.
- Install three M6 x 35 mm bolts in the threaded holes on the sealing flange - arrows -.
- Install bolts in an alternating sequence (maximum one 1/ 2 turn (180°) per bolt at a time) in the sealing flange and press the sealing flange and sensor wheel off the crankshaft.
Sealing Flange with Sensor Wheel, Installing
• Sealing flange with PTFE-seal is equipped with a sealing lip support ring. This support ring serves the same function of an assembly sleeve and must not be removed before installation.
• The sealing flange and sensor wheel must not be separated or rotated after being removed from the replacement part packaging.
• The sensor wheel retains the installation position via being located on the locating pin of the assembly tool (T10134).
• The sealing flange and seal are one unit and may only be replaced together with the sensor wheel.
• The assembly tool (T10134) retains the installation position to the crankshaft via a guide pin, which is guided into the bore of the crankshaft.
Assembly tool (T10134)
A Tension surface
B Nut
C Assembly bell
D Locating pin
E Socket head hex bolt
F Guide pin for diesel engines (black handle)
G Guide pin for gasoline engines (red handle)
A - Installing Seal with Sensor Wheel on the Assembly Tool (T10134)
- Screw on the nut - B - until shortly before the tension surface - A - of the threaded spindle.
- Tension the assembly tool (T10134) in a vise on the tension surface - A - of the threaded spindle.
- Press assembly bell - C - downward so that it rests on the nut - B - - arrow -.
- Install hex nut on the threaded spindle until the inner section of the assembly tool is level with the assembly bell.
- Remove securing clip - arrow - from the new sealing flange.
• The sensor wheel must not be removed from or rotated in the sealing flange.
- The locating pin - A - on the sensor wheel - C - must align with the marking - B - on the sealing flange.
- Place front side of sealing flange onto a clean level surface.
- Press sealing lip support ring - A - in direction of - arrow - downward until it rests on the level surface.
- The upper edge of the sensor wheel and the front edge of the sealing flange must align - arrows -.
- Place front side of the sealing flange on the assembly tool (T10134) so the locating pin - B - is positioned in the bore - A - on the sensor wheel.
• Make sure that the sealing flange is positioned flat on the assembly tool.
- While tightening the three knurled bolts - A -, press the sealing flange and sealing lip support ring - B - onto the surface of the assembly tool (T10134) so the locating pin does not slip out of the bore on the sensor wheel.
• When installing the sealing flange, make sure the sensor wheel remains in the assembly tool.
B - Installing Assembly Tool with Sealing Flange on Crankshaft Flange
Requirements
• Crankshaft flange must be free of oil and grease.
• Engine cylinder 1 is at TDC.
Procedure
- Screw nut - B - to the end of the threaded spindle.
- Press threaded spindle of assembly tool (T10134) in direction of - arrow - until nut - B - rests on assembly bell - A -.
- Align flat side of assembly bell to sealing surface on oil pan side of cylinder block.
- Secure assembly tool (T10134) onto the crankshaft flange using the socket head hex bolts - A -.
• Screw socket head hex bolts - A - approximately 5 threads into the crankshaft flange.
- Install two bolts M7 x 35 mm - A - in the cylinder block to guide the sealing flange.
C - Bolting Assembly Tool to Crankshaft Flange
- Push assembly bell - C - by hand in direction of - arrow - until the sealing lip support ring - B - rests on the crankshaft flange - A -.
- Push guide pin for diesel engines (black handle) - D - into the crankshaft bore. Thereby the sensor wheel is retained in the final installed position.
• Do not insert the guide pin for gasoline engines (black handle) - F - into the crankshaft threaded bore.
- Tighten both hex socket bolts on the assembly tool by hand.
- Screw nut - E - onto the threaded spindle so far by hand, until it rests against the assembly bell - C -.
D - Installing the Sensor Wheel on the Crankshaft Flange with the Assembly Tool
- Tighten assembly tool (T10134) nut to 35 Nm with the torque wrench (V.A.G 1331) and 24 mm socket (V.A.G 1332/11).
• Tightening specifications: 35 Nm.
• After tightening the nut to 35 Nm, a minimal air gap must still be present between the cylinder block and sealing flange.
E - Sensor Wheel on Crankshaft, Checking Installation Position
- Screw nut - E - to the end of the threaded spindle.
- Screw two bolts - A - out of the cylinder block.
- Screw three knurled bolts - B - out of the sealing flange.
- Remove assembly tool (T10134).
- Remove sealing lip support ring.
The installed position of the sensor wheel on the crankshaft is exact, if a gap - a - of 0.5 mm is present between the crankshaft flange - A - and sensor wheel - B -.
- Set a caliper gauge onto the crankshaft flange.
- Measure gap - a - between the crankshaft flange and sensor wheel.
If dimension - a - is too small:
- Press sensor wheel again.
If dimension - a - is obtained:
- Tighten new sealing flange bolts alternating in a diagonal sequence:
• Tightening specifications --> [ item 7, 15 Nm ] Service and Repair.
- Install engine speed sensor. Refer to --> [ Engine Speed Sensor ] Service and Repair.
- Install oil pan. Refer to --> [ Oil Pan ] Service and Repair.
- Install intermediate plate --> [ 6 Intermediate Plate ] Service and Repair.
- Install flywheel with new bolts:
• Tightening specifications, refer to --> [ (item 4) 60 Nm plus an additional / turn (90°) ] Service and Repair.
F - Sensor Wheel, Pressing On
- Secure assembly tool (T10134) onto the crankshaft flange using the socket head hex bolts - A -.
- Tighten both hex socket bolts - A - by hand.
- Push assembly tool (T10134) onto the sealing flange by hand.
- Screw nut - E - onto threaded spindle so far by hand, until it rests against the assembly bell - C -.
- Tighten assembly tool (T10134) nut to 35 Nm with the torque wrench (V.A.G 1331) and 24 mm socket (V.A.G 1332/11):
• Tightening specifications 40 Nm.
- Check installed position of the sensor wheel on the crankshaft again.
If dimension - a - is too small:
- Tighten hex nut on assembly tool (T10134):
• Tightening specifications 45 Nm.
- Check installed position of the sensor wheel on the crankshaft again.