Crankshaft Seal Retainer: Service and Repair
Crankshaft Sealing Flange, Flywheel Side
Special tools, testers and auxiliary items required
• Assembly Tool (T10134)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Tool Insert AF24 (V.A.G 1332/11)
• Caliper Gauge
• Three M6 x 35 Bolts
• Two M7 x 35 Bolts
Removing
- Remove the transmission, refer to one of the following:
With a manual transmission.
With a Direct Shift Gearbox (DSG(R)).
- Remove the flywheel - item 5 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.
- Remove the intermediate plate - item 6 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.
- Rotate the crankshaft to Top Dead Center (TDC) for cylinder 1, as illustrated.
- Remove the oil pan, refer to the following:
Engine code CJAA, refer to => [ Oil Pump and Oil Pan Overview ] Service and Repair.
• To improve clarity, the steps/graphics are shown with the engine removed.
• The steps are the same with the engine installed and removed.
- Remove the engine speed sensor. Refer to => [ Engine Speed Sensor G28 ] Service and Repair.
- Remove the sealing flange bolts.
• The sealing flange and sensor wheel are pressed off the crankshaft using three M6 x 35 mm bolts.
- Install the three M6 x 35 mm bolts in the threaded holes - arrows - on the sealing flange.
- Tighten the 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.
Installing
• The sealing flange with a Polytetrafluoroethylene (PTFE) seal is equipped with a sealing lip support ring. This support ring serves the same function as 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 installed 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 installed 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 bolt
F Guide pin for diesel engines (black handle)
G Guide pin for gas engines (red handle)
Installing the Seal with Sensor Wheel to the Assembly Tool (T10134)
- Screw on the nut - B - until shortly before the tension surface of the threaded spindle - A -.
- Secure the assembly tool (T10134) in a vise on the flat surface of the threaded spindle - A -.
- Push the assembly bell - C - downward so that it rests on the nut - B - - arrow -.
- Install the nut on the threaded spindle until the inner section of the assembly tool is level with the assembly bell - C -.
- Remove the 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 mark - B - on the sealing flange.
- Place the front side of the sealing flange on a clean level surface.
- Press the sealing lip support ring - A - in the - direction of the 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 the 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 the sealing flange is positioned flat on the assembly tool.
- Push the sealing flange and the sealing lip support ring - B - onto the surface of the assembly tool (T10134) while tightening the 3 knurled thumb screws - A - so that the securing pin cannot slip out of the hole in the sensor wheel.
• Make sure the sensor wheel remains fixed inside the assembly tool when installing the sealing flange.
Installing the Assembly Tool (T10134) with Sealing Flange to the Crankshaft Flange
Requirements
• Crankshaft flange must be free of oil and grease.
• The engine is at TDC cylinder 1.
Procedure
- Screw the nut - B - to the end of the threaded spindle.
- Press the threaded spindle of the assembly tool (T10134) in the - direction of the arrow - until the nut - B - rests on the assembly bell - A -.
- Align the flat side of the assembly bell to the sealing surface on the oil pan side of the cylinder block.
- Secure the assembly tool (T10134) onto the crankshaft flange using the socket head bolts - A -.
• Screw the socket head bolts - A - approximately 5 threads into the crankshaft flange.
- Install two M7 x 35 mm bolts - A - to guide the sealing flange into the cylinder block.
Attach the Assembly Tool (T10134) to the Crankshaft Flange
- Push the assembly bell - C - by hand in the - direction of the arrow - until the sealing lip support ring - B - rests on the crankshaft flange - A -.
- Push the 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 gas engines (red handle) - F - into the crankshaft threaded bore.
- Tighten both bolts on the assembly tool by hand.
- Install the nut - E - onto the threaded spindle by hand, until it rests on the assembly bell - C -.
Installing the Sensor Wheel on the Crankshaft Flange using the Assembly Tool (T10134)
- Tighten the nut on the assembly tool (T10134) using torque wrench (5-50 Nm) (V.A.G 1331) and the tool insert AF24 (V.A.G 1332/11).
• Tightening specification: 35 Nm.
• After tightening the nut to 35 Nm, a minimal air gap must still be present between the cylinder block and sealing flange.
Sensor Wheel to Crankshaft, Checking the Installed Position
- Screw the nut - E - to the end of the threaded spindle.
- Remove the two bolts - A - out of the cylinder block.
- Remove the three knurled thumb screws - B - out of the sealing flange.
- Remove the assembly tool (T10134).
- Remove the 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 the gap - a - between the crankshaft flange and sensor wheel.
If dimension - a - is too small:
- Press the sensor wheel on again.
If dimension - a - is obtained:
- Tighten the new sealing flange bolts alternating in a diagonal sequence:
• Tightening specifications, see - item 7 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.
- Install the engine speed sensor. Refer to => [ Engine Speed Sensor G28 ] Service and Repair.
- Install the oil pan, refer to the following:
Engine code CJAA, refer to => [ Oil Pump and Oil Pan Overview ] Service and Repair.
- Install the intermediate plate - item 6 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.
- Install the flywheel with new bolts:
• Tightening specifications, see - item 4 - in the => [ Sealing Flange and Flywheel Overview ] Service and Repair.
Sensor Wheel, Pressing On Again
- Secure the assembly tool (T10134) onto the crankshaft flange using the socket head bolts - A -.
- Tighten both the socket head bolts - A - by hand.
- Push the assembly tool (T10134) onto the sealing flange by hand.
- Install the nut - E - onto the threaded spindle by hand, until it rests on the assembly bell - C -.
- Tighten the nut on the assembly tool (T10134) using a torque wrench (5-50 Nm) (V.A.G 1331) and the tool insert AF24 (V.A.G 1332/11) :
• Tightening specification: 40 Nm.
- Check the installed position of the sensor wheel on the crankshaft again.
If dimension - a - is too small:
- Tighten the nut on the assembly tool (T10134) :
• Tightening specification: 45 Nm.
- Check the installed position of the sensor wheel on the crankshaft again.