Sealing Flange Transmission Side: Notes

Special tools and workshop equipment required 

• Assembly Tool T10134
• Torque Wrench 5-50 Nm V.A.G 1331
• Tool Insert AF 24 V.A.G 1332/11

Special tools and workshop equipment required 

• Caliper gauge
• Three M6 x 35 hex bolts
• Two M7 x 35 hex bolts

-- Remove the transmission. Refer to REMOVAL AND INSTALLATION .

-- Remove the flywheel. Refer to FLYWHEEL .

-- Remove the intermediate plate. See -item  7-.

-- Rotate the crankshaft to TDC cylinder 1 as shown.

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

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-- Remove the oil pan. Refer to OIL PAN .

-- Remove the Engine Speed Sensor -G28- -arrow-. Refer to Engine Speed Sensor -G28- .

Fig 2: Identifying Engine Speed (RPM) Sensor G28

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

Fig 3: Tightening Sequence

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-- Screw three M6 x 35 mm screws into the threaded holes on the sealing flange -arrows-.

Fig 4: Identifying Sealing Flange Threaded Holes

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-- Install 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 sensor wheel

Special tools and workshop equipment required 

• Caliper gauge
• Three M6 x 35 hex bolts
• Two M7 x 35 hex bolts

Assembly Tool T10134

Fig 5: Identifying Assembly Tool T10134

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A -

Tension surface

B -

Nut

C -

Assembly bell

D -

Securing pin

E -

Hex socket head bolt

F -

Guide pin for diesel engines (black handle)

G -

Guide pin for gasoline engines (red handle)

1. Attach seal and sensor wheel to the Assembly Tool T10134.

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

   Fig 6: Identifying Assembly Tool T10134

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   -- Mount the Assembly Tool T10134 in a vise by the tension surface -A- on the threaded spindle.

   Fig 7: Identifying Assembly Tool T10134 Tensioned In Vise On Tension Surface Of Threaded Spindle

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   -- Push the assembly bell -C- downward so that it is touching the nut -B-.

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

   -- Remove the circlip -arrow- from the new sealing flange.

   Fig 8: 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 marking -B- on the sealing flange.

   Fig 9: Identifying Locating Pin On Sensor Wheel Aligns With Marking On Sealing Flange

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

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

   Fig 10: 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 11: Identifying Upper Edge Of Sensor Wheel And Front Edge Of Sealing Flange Align

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   -- Mount 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.

   Fig 12: 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.

   -- Press the sealing flange and the sealing lip support ring -B- onto the surface of the Assembly Tool T10134 while tightening the three knurled bolts -A- so that the securing pin cannot slip out of the hole in the sensor wheel.

   Fig 13: Identifying Sealing Flange And Sealing Lip Support Ring Pressed On Assembly Tool T10134

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   NOTE:

   Make sure the sensor wheel remains fixed inside the assembly tool when installing the sealing flange.

2. Attach Assembly Tool T10134 with sealing flange on crankshaft flange.
   • Crankshaft flange must be free of oil and grease.
   • The engine is at TDC cylinder 1.

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

   Fig 14: Identifying Threaded Spindle Pressed Of Assembly Tool T10134 Until Nut Rests On Assembly Bell

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   -- Press the threaded spindle on 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 bolt -A- to the crankshaft flange.

   Fig 15: Identifying Assembly Tool T10134 Secured Onto Crankshaft Flange Using Socket Head Hex Bolts

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   NOTE: Screw the socket head hex bolts -A- approximately five threads into the crankshaft flange.

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

   Fig 16: Identifying Bolts Screwed Into Cylinder Block To Guide Sealing Flange

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3. Fasten the Assembly Tool T10134 to the crankshaft flange.

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

   Fig 17: 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 hole in the crankshaft. Thereby the sensor wheel is retained in the final installed position.

   NOTE: Do not insert the guide pin for gasoline engines (red handle) -F- into the crankshaft threaded bore.

   -- Hand-tighten both socket head hex 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 flange with the Assembly Tool T10134.

   -- Tighten the nut on the Assembly Tool T10134 to 35 Nm using Torque Wrench 5-50 Nm V.A.G 1331 and Socket Wrench V.A.G 1332/11.

   Fig 18: Identifying Sensor Wheel Pressed With Assembly Tool T10134 Onto Crankshaft Flange

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   NOTE: After tightening the nut to 35 Nm, a minimal air gap must still be present between the cylinder block and sealing flange.
5. Check the installed position of the sensor wheel on the crankshaft.

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

   Fig 19: Checking Installed Position Of Sensor Wheel On Crankshaft

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

   -- Remove the three knurled bolts -B- from the sealing flange.

   -- Remove the hex socket head bolt -A- and remove the Assembly Tool T10134.

   Fig 20: Identifying Assembly Tool T10134 Secured Onto Crankshaft Flange Using Socket Head Hex Bolts

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   -- 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-.

   Fig 21: Identifying Installed Position Of Sensor Wheel On Crankshaft Is Exact

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   -- Set a caliper gauge onto the crankshaft flange.

   Fig 22: Identifying Caliper Gauge Set Onto Crankshaft Flange

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

   Fig 23: Identifying Installed Position Of Sensor Wheel On Crankshaft Is Exact

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   If dimension -a- is too small:

   -- Press on the sensor wheel, refer to SEALING FLANGE TRANSMISSION SIDE => .

   If dimension -a- is obtained:

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

   -- Install the Engine Speed Sensor -G28- -arrow-. Refer to Engine Speed Sensor -G28- .

   Fig 24: Identifying Engine Speed (RPM) Sensor G28

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   -- Install the oil pan. Refer to OIL PAN .

   -- Install intermediate plate, refer to -item  7-.

   -- Install the flywheel with new bolts.

6. Press on the sensor wheel.

   -- Secure the Assembly Tool T10134 with the hex socket head bolt -A- to the crankshaft flange.

   Fig 25: Identifying Assembly Tool T10134 Secured Onto Crankshaft Flange Using Socket Head Hex Bolts

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   -- Hand-tighten both socket head hex 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-.

   Fig 26: Checking Installed Position Of Sensor Wheel On Crankshaft

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   -- Tighten the nut on the Assembly Tool T10134 to 40 Nm using torque wrench 5-50 Nm V.A.G 1331 and Socket Wrench V.A.G 1332/11.

   Fig 27: Identifying Sensor Wheel Pressed With Assembly Tool T10134 Onto Crankshaft Flange

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   -- Check the sensor wheel installed position on the crankshaft. See -item  5.

   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. See -item  5.