Crankshaft Sealing Flange, Flywheel Side: Notes

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment 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:

Vehicles with a manual transmission, refer to TRANSMISSION .
Vehicles with a Direct Shift Gearbox (DSG®), refer to TRANSMISSION .

-- Remove the flywheel -item 5- in the SEALING FLANGE AND FLYWHEEL OVERVIEW .

-- Remove the intermediate plate -item 6- in the SEALING FLANGE AND FLYWHEEL OVERVIEW .

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

Fig 1: Identifying Crankshaft Rotated To Top Dead Center (TDC) For Cylinder 1

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-- Remove the oil pan, refer to one of the following:

Engine code CBEA, refer to OIL PUMP, PAN AND BALANCE SHAFT MODULE OVERVIEW .

Engine code CJAA, refer to OIL PUMP AND OIL PAN OVERVIEW .

NOTE:

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 -G28-. Refer to Engine Speed Sensor -G28- .

-- Remove the sealing flange bolts.

NOTE:

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.

Fig 2: Identifying Sealing Flange Threaded Holes

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-- 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

NOTE:

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

Fig 3: Identifying Assembly Tool T10134

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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-.

Fig 4: Identifying Assembly Tool T10134

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-- Secure the assembly tool T10134 in a vise on the flat surface of the threaded spindle -A-.

Fig 5: Identifying Tensioning Assembly Tool T10134 In Vise To Tension Surface Of Threaded Spindle

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-- 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.

Fig 6: Identifying Securing Clip From New Sealing Flange

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NOTE:

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.

Fig 7: Locating Pin On Sensor Wheel Aligns With Marking On Sealing Flange

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-- 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.

Fig 8: Identifying Sealing Lip Support Ring Pressed Until It Rests On Level Surface

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-- The upper edge of the sensor wheel and the front edge of the sealing flange must align -arrows-.

Fig 9: Identifying Upper Edge Of Sensor Wheel And Front Edge Of Sealing Flange Align

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-- 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.

Fig 10: Identifying Front Side Of Sealing Flange Placed Onto Assembly Tool T10134 To Position Locating Pin In Bore Of Sensor Wheel

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NOTE:

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.

Fig 11: Identifying Sealing Flange And Sealing Lip Support Ring Pressed Onto Surface Of Assembly Tool T10134 So Locating Pin Can No Longer Slip Out Of Bore Of Sensor Wheel

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NOTE:

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.

Fig 12: Identifying Threaded Spindle Pressed Of Assembly Tool T10134 Until Nut Rests On Assembly Bell

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-- 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-.

Fig 13: Identifying Assembly Tool T10134 Secured Onto Crankshaft Flange Using Socket Head Hex Bolts

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NOTE:

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.

Fig 14: Identifying Bolts Screwed Into Cylinder Block To Guide Sealing Flange

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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-.

Fig 15: Identifying Assembly Bell Pushed Until Sealing Lip Support Ring Rests On Crankshaft Flange

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-- 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.

NOTE:

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.

Fig 16: Identifying Sensor Wheel Pressed With Assembly Tool T10134 Onto Crankshaft Flange

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Tightening specification: 35 Nm.

NOTE:

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