Removing and installing sealing flange on gearbox side

Special tools and workshop equipment required

Flared ring spanner tool insert AF 24 -V.A.G 1332/11-

Depth gauge -VAS 6082-

Assembly tool -T10134-

Locking pin -T10340-

Bolt M6x35 (3x)

Procedure

Gearbox removed.

• Remove flywheel → Chapter.

• Remove intermediate plate -1- from dowel sleeves -arrows A-.
• Guide intermediate plate -1- upwards.
• While doing so, pull retaining lug -arrow B- of intermediate plate -1- out of recess behind sealing flange.

Setting crankshaft to “TDC” position:

• Remove ignition coil with output stage for cylinder 1 → Chapter.
• Remove spark plug from cylinder 1.

Setting correct position of crankshaft for screwing in locking pin:

• Carefully insert a screwdriver with a shaft length of at least 250 mm in -direction of arrow- into spark plug hole so that it contacts piston crown.
• Turn crankshaft in direction of engine rotation to “BDC” for no. 1 cylinder.

• Turn crankshaft further in direction of engine rotation, until screwdriver has moved 35 mm upwards in -direction of arrow-.

• Unscrew plug for “TDC” hole in cylinder block → Fig..
• Unscrew plug for “TDC” hole in cylinder block.

Risk of damage to engine

In this case, proceed as follows:

Unscrew locking pin.

Turn crankshaft 90° in direction of engine rotation.

Turn crankshaft in direction of engine rotation as far as stop.

• Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 N·m.
• Rotate crankshaft in normal direction of rotation as far as stop.

The locking pin now rests against the crank web.

Locking pin -T10340- locks crankshaft in direction of engine rotation only.

• Remove sump (bottom section) → Chapter „Removing and installing lower part of sump“.
• Remove upper part of sump → Chapter „Removing and installing upper part of sump“.
• Remove engine speed sender -G28- → Chapter.

• Unscrew bolts -arrows- for sealing flange -1-.

• To press off, screw 3 M6 x 35 bolts -arrows- into sealing flange -1-.

• Screw bolts alternately into sealing flange not more than ¹/₂ turn at a time.
• Remove sealing flange -1- together with sender wheel -2-.

Pressing in sealing flange with sender wheel

Components of assembly tool -T10134-:

Fitting sealing flange with sender wheel on assembly tool -T10134-:

• Screw on nut -B- until just before it touches the clamping surface -A- of the threaded spindle.

• Clamp assembly device -T10134- at clamping surface -A- of threaded spindle in a vice -1-.
• Press assembly housing -C- downwards until it rests against nut -B-.

Inner part of assembly tool and assembly housing must be at same height.

• If fitted, remove securing clip -arrow- from new sealing flange.

Note

• Place sealing flange with front side facing down on a clean level surface.
• Push sealing lip support ring -1- downwards in -direction of arrow- until it rests against level surface.

• Place sealing flange -1- with front side facing downwards onto assembly tool -T10134- so that locating pin -D- is seated in hole -3- in sender wheel hole -2-.

The sealing flange must rest flat against the assembly tool.

• Screw knurled screws -H- into sealing flange -1-.
• Press sealing flange -1- and sealing lip support ring -2- against surface of assembly tool -T10134- whilst tightening knurled screws.
• This prevents locating pin from slipping out of sender wheel hole.
• When installing sealing flange, ensure that sender wheel remains fixed in assembly device.

Mounting assembly tool -T10134- with sealing flange -1- on crankshaft flange:

The crankshaft flange must be free of grease and oil.

Engine is at “TDC” position → Anchor.

• Screw on nut -B- until it reaches end of threaded spindle.
• Press threaded spindle of assembly tool -T10134- in -direction of arrow-, until nut -B- rests against assembly housing -C-.
• Align flat side of assembly housing to sealing surface of cylinder block on sump side.

• Attach assembly tool -T10134- together with sealing flange -1- to crankshaft flange -2-.
• To do this, screw hexagon socket head bolts -E- into crankshaft flange (approx. 5 full turns) using a hexagon key.
• Push guide pin for petrol engines (red knob) -F- into crankshaft flange.

• To guide sealing flange -1-, screw two M6Ч35 mm bolts -2- into cylinder block.

Bolting assembly tool -T10134- onto crankshaft flange:

• Push assembly housing -C- by hand in -direction of arrow- until sealing lip support ring -1- rests against crankshaft flange -2-.
• Make sure that guide pin for petrol engines (red knob) -F- is properly seated in hole in crankshaft. This ensures that the sender wheel reaches its final installation position.

• Tighten the two hexagon socket head bolts of assembly tool hand-tight.
• Screw nut -B- by hand onto threaded spindle until it rests against assembly housing -C-.

Pressing sender wheel onto crankshaft flange using assembly tool -T10134-:

• Tighten nut -B- of assembly tool -T10134- to 35 N·m.

Checking sender wheel installation position on crankshaft:

• Screw on nut -B- until it reaches end of threaded spindle.
• Unscrew the two bolts -2- from cylinder block.
• Pull guide pin for petrol engines (red knob) -F- out of crankshaft flange.
• Unscrew knurled screws -H- from sealing flange -1-.
• Unbolt assembly tool -T10134- from crankshaft flange, unscrewing hexagon socket head bolts -E- from crankshaft flange.
• Remove sealing lip support ring.

• Position depth gauge -VAS 6082- on crankshaft flange -2-.

• Measure distance -a- between crankshaft flange -2- and sender wheel -1-.

Specification: dimension -a- = 0.5 mm

• If specification is not achieved, press sender wheel further in → Anchor.
• If specification is achieved, proceed with subsequent work steps → Anchor.

Re-pressing sender wheel:

• Secure assembly tool -T10134- on crankshaft flange -1-.
• Make sure that locating pin of assembly tool -T10134- is properly seated in sender wheel hole.
• Tighten hexagon socket head bolts -E- by hand.
• Push assembly tool -T10134- by hand against sealing flange -1-.
• Screw nut -B- by hand onto threaded spindle until it rests against assembly tool -T10134-.
• Push guide pin for petrol engines (red knob) -F- into crankshaft flange.
• Screw knurled screws -H- into sealing flange -1-.
• To guide sealing flange, screw two M6Ч35 mm bolts -2- into cylinder block.

• Tighten nut -B- of assembly tool -T10134- to 40 N·m.
• Check sender wheel installation position on the crankshaft again → Anchor.
• If the specification is not achieved, tighten nut of assembly tool -T10134- to 45 N·m.
• Check sender wheel installation position on the crankshaft again → Anchor.

Reassembly

• Tighten bolts for sealing flange → Fig..
• Install lower part of sump → Chapter „Removing and installing lower part of sump“.
• Install upper part of sump → Chapter „Removing and installing upper part of sump“.
• Install intermediate plate → Fig..
• Install flywheel → Chapter.

Specified torques

→ Fig. „“Plug for TDC drilling in cylinder block at rear – specified torque”“

→ Chapter „Assembly overview - cylinder block, gearbox end“

Engine speed sender -G28- → Chapter „Assembly overview - ignition system“