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Home >> Volkswagen >> 2005 >> Jetta TDI, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.9L - Crankshaft, Cylinder Block - Engine Code(S): BKC, BLS, BRM & BXE (A5 Platform) >> 13 Engine - Crankshaft, Cylinder Block >> Removal And Installation >> Sealing Flange, Flywheel Side >> Notes

Sealing Flange, Flywheel Side: Notes

Special Tools And Workshop Equipment Required 

Pressing Out 

NOTE:

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 dual mass flywheel DUAL MASS FLYWHEEL .

-- Remove the intermediate plate.

-- Set engine to TDC cyl. 1 TOOTHED BELT .

-- Remove oil pan OIL PAN .

-- Remove the engine speed (RPM) sensor -G28- -arrow- using a commercially available ball head socket insert.

Fig 1: Identifying Engine Speed (RPM) Sensor G28
GWWN13-10021Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the sealing flange bolts.

NOTE:

Sealing flange and sensor wheel are pressed off together from the crankshaft using three bolts M6 x 35 mm.

-- Screw three bolts M6 x 35 mm into the threaded holes -arrows- of the sealing flange.

Fig 2: Identifying Sealing Flange Threaded Holes
GWWN13-10022Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Screw the bolts alternating (max. one 1 /2 turn (180°) per bolt) into the sealing flange and press the sealing flange together with the sensor wheel off from the crankshaft.

Pressing In 

NOTE:

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 

Fig 3: Identifying Assembly Tool T10134
GWWN13-10023Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A - Tension surface

B - Nut

C - Assembly bell

D - Locating pin

E - Socket head hex bolt

F - Guide pin for diesel engines (red handle)

G - Guide pin for gasoline engines (black handle)

Mounting Seal with Sensor Wheel on Assembly Tool 

-- Screw on the nut -B- until shortly before the tension surface -A- of the threaded spindle.

Fig 4: Identifying Assembly Tool T10134
GWWN13-10023Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tension the assembly tool T10134 in a vise on the tension surface -A- of the threaded spindle.

Fig 5: Identifying Assembly Tool T10134 Tensioned In Vise On Tension Surface Of Threaded Spindle
GWWN13-10024Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the assembly bell -C- downward so that it rests on the nut -B- -arrow-.

NOTE:

Inner part of the assembly tool and assembly bell must be on the same level.

-- Remove the securing clip -arrow- from the new sealing flange.

Fig 6: Identifying Securing Clip From New Sealing Flange
GWWN13-10025Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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 marking -B- on the sealing flange.

Fig 7: Identifying Locating Pin On Sensor Wheel Aligns With Marking On Sealing Flange
GWWN13-10026Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the front side of the sealing flange onto a clean level surface.

-- Press the sealing lip support ring -A- in -direction of arrow- downward until it rests on the level surface.

Fig 8: Identifying Sealing Lip Support Ring Pressed Until It Rests On Level Surface
GWWN13-10027Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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
GWWN13-10028Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the front side of the sealing flange onto the assembly tool T10134 so that the locating pin -B- is positioned in the bore -A- of 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
GWWN13-10029Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

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

-- While tightening the knurled bolts -A-, press the sealing flange and sealing lip support ring -B- onto the surface of the assembly tool T10134 so that the locating pin can no longer slip out of the bore of 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
GWWN13-10030Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

Make sure that, when installing the sealing flange, the sensor wheel remains located in the assembly tool.

Mounting Assembly Tool with Sealing Flange on Crankshaft Flange 

-- 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
GWWN13-10045Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Position the flattened side of the assembly bell toward the oil pan sealing surface side of the crankcase.

-- Secure the assembly tool T10134 onto the crankshaft flange using the socket head hex bolts -A-.

Fig 13: Identifying Assembly Tool T10134 Secured Onto Crankshaft Flange Using Socket Head Hex Bolts
GWWN13-10044Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

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

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

Fig 14: Identifying Bolts Screwed Into Cylinder Block To Guide Sealing Flange
GWWN13-10031Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolting Assembly Tool to Crankshaft Flange 

-- Push the assembly bell -C- by hand in -direction of 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
GWWN13-10032Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the guide pin for diesel engines (red handle) -D- into the bore of the crankshaft. Thereby the sensor wheel is retained in the final installed position.

NOTE:

The guide pin for gasoline engines (black handle) -F- must not be inserted into the threaded bore of the crankshaft.

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

-- Screw the nut -E- onto the threaded spindle so far by hand, until it rests against the assembly bell -C-.

Pressing Sensor Wheel with Assembly Tool to Crankshaft Flange 

-- Tighten the nut of the assembly tool T10134 with torque Wrench V.A.G 1331 and socket insert V.A.G 1332/11 to 35 Nm.

Fig 16: Identifying Sensor Wheel Pressed With Assembly Tool T10134 Onto Crankshaft Flange
GWWN13-10033Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE:

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

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