Rear Crankshaft Main Bearing Seal: Service and Repair

Sealing Flange, Transmission Side

Special tools, testers and auxiliary items required

• Assembly Tool (T10134)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Tool Insert AF 24 (V.A.G 1332/11)

• Caliper Gauge

• Three M6 x 35 bolts

• Two M7 x 35 bolts

Removing

- Remove the dual mass flywheel. Refer to => [ Dual Mass Flywheel ] Dual Mass Flywheel.

- Remove the intermediate plate.

- Rotate the crankshaft to Top Dead Center (TDC) for cylinder 1 as illustrated.






- Remove the oil pan. Refer to => [ Oil Pan ] Oil Pan.

• The engine is shown removed, in the illustrations.

• The procedure is the same with the engine installed.

- Remove the engine speed sensor - arrow -, refer to => [ Engine Speed Sensor G28 ] Service and Repair.






- Remove the sealing flange bolts - 1 through 6 -.






• 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 on the sealing flange - arrows -.






- Tighten the bolts in an alternating sequence (maximum one 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 a 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 Threaded spindle
B Nut
C Assembly bell
D Locating pin
E Hex socket head bolt
F Guide pin for diesel engines (black handle)
G Guide pin for gas engines (red handle)

1.) Attach the seal and sensor wheel to the assembly tool (T10134) :

- Turn the nut - B - on the threaded spindle - A - just up to the tension surface.






- Install the assembly tool (T10134) in a vise on the flats of the threaded spindle - A -.






- Push the assembly bell - C - downwards until it touches the nut - B - - arrow -.

- Install the nut - B - on the threaded spindle - A - until the inner section of the assembly tool is level with the assembly bell - C -.

- Remove the retainer - 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 sealing flange on a clean even surface with the front side facing up.

- Press the sealing lip support ring - A - downward in the - direction of the arrows - 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 -.






- Install the sealing flange with the front side on the assembly tool (T10134) so that the securing pin - B - fits into the hole - A - in the sensor wheel.






• Make sure the sealing flange is positioned flat on the assembly tool.

- Press 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.

2.) Attach the assembly tool (T10134) with sealing flange to the crankshaft:

• Crankshaft must be free of oil and grease.

• The engine is at TDC for cylinder. 1.

- Turn the nut - B - all the way to the end of the threaded spindle.






- Press the threaded spindle on the assembly tool (T10134) in the - direction of the arrow - until the nut - B - touches the assembly bell - A -.

- Align the flat side of the assembly bell with the oil pan side sealing surface of the crankcase.

- Secure the assembly tool (T10134) with the hex socket head bolts - A - to the crankshaft.






• Screw the hex socket head bolts - A - approximately 5 threads into the crankshaft.

- Install two M7 x 35 mm bolts - A - in the cylinder block to guide the sealing flange.






3.) Fasten the assembly tool (T10134) to the crankshaft:

- Slide the assembly bell - C - in the - direction of the arrow - by hand until the sealing lip support ring - B - touches the crankshaft - A -.






- Install the guide pins for diesel engines (black handle) - D - into the hole in the crankshaft. The sensor wheel will be in its final installed position.

• Do not insert the guide pin for gas engines (red handle) - F - into the crankshaft threaded bore.

- Hand tighten both hex socket head bolts of the assembly tool.

- Install the nut - E - as far as possible on the threaded spindle by hand until the nut touches the assembly bell - C -.

4.) Installing the sensor wheel on the crankshaft with the assembly tool (T10134) :

- Tighten the nut for the assembly tool (T10134) using the torque wrench (5-50 Nm) (V.A.G 1331) and the tool insert AF 24 (V.A.G 1332/11) to 35 Nm.






• After tightening the nut to 35 Nm, a minimal air gap must still be present between the cylinder block and sealing flange.

5.) Checking the sensor wheel installed position on the crankshaft:

- Install the nut - E - all the way to the end of the threaded spindle.






- Remove the 2 bolts - A - from the cylinder block.

- Remove the 3 knurled thumb screws - B - from the sealing flange.

- Remove the hex socket head bolt - A - and 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 of 0.5 mm - a - is present between the crankshaft flange - A - and sensor wheel - B -.






- Set a caliper gauge onto the crankshaft flange.






- Measure the distance - a - between the crankshaft flange and the sensor wheel.






If dimension - a - is too small:

- Press on the sensor wheel

If dimension - a - is obtained:

- Tighten the new sealing flange bolts alternating in a diagonal sequence.

- Install the engine speed sensor - arrow -, refer to=> [ Engine Speed Sensor G28 ] Service and Repair.






- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Install the intermediate plate.

- Install the flywheel with new bolts.

Tightening Specifications






6.) Press on the sensor wheel:

- Secure the assembly tool (T10134) with the hex socket head bolt - A - to the crankshaft flange.






- Hand tighten both hex socket head bolts.

- Attach the assembly tool (T10134) onto the sealing flange by hand.

- Install the nut - E - as far as possible on the threaded spindle by hand until the nut touches the assembly bell - C -.






- Tighten the nut for the assembly tool (T10134) with the torque wrench (5-50 Nm) (V.A.G 1331) and tool insert AF 24 (V.A.G 1332/11) to 40 Nm.






- Check the sensor wheel installed position on the crankshaft.

If dimension - a - is again too small:

- Tighten the assembly tool (T10134) nut to 45 Nm.

- Check the sensor wheel installed position on the crankshaft.