Audi Workshop Service and Repair Manuals

Renewing sealing flange

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Open ring spanner -V.A.G 1332/11-

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Assembly tool -T10134-

t	Adapter for dial gauge -T10170-

t  Locking pin -T10340-

t  Depth gauge -VAS 6082- t  Feeler gauge t  Bolt M6x35 (3x)

Pressing sealing flange with sender wheel off crankshaft l  Gearbox removed → Rep. gr.34.   Note For illustration purposes, the procedure is shown with the engine removed. –  Remove flywheel → Chapter. –  Remove engine speed sender -G28- → Rep. gr.28.

–  Press intermediate plate off dowel sleeves -arrows B- and detach from top of sealing flange -arrow A-

–  Apply puller -T10094 A- to ignition coil for cylinder 1, pull out ignition coil and at the same time unplug electrical connector at ignition coil for cylinder 1. –  Remove spark plug for cylinder 1 with spark plug socket and extension -3122 B-.

–  Screw adapter for dial gauge -T10170- into spark plug hole as far as the stop. –  Insert dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Rotate crankshaft in normal direction of rotation to „TDC“. l  „TDC“ = maximum measured value on dial gauge.

–  Unscrew plug -arrow- for „TDC“ hole on cylinder block.

Caution Risk of damage to engine. Locking pin -T10340- must be screwed in with crankshaft at „TDC“ position. –  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm.   Note The locking pin -T10340- locks the crankshaft only in the direction of engine rotation. –  Remove sump → Chapter.

–  Remove bolts for sealing flange.   Note The sealing flange is pressed off the crankshaft together with the sender wheel. –  To press off, screw 3 bolts M6x35 -arrows- alternately into sealing flange not more than 1/2 turn at a time. –  Take off sealing flange with sender wheel. Pressing in sealing flange with sender wheel l  Tightening torque → Chapter „Flywheel and sealing flange - exploded view“   Note t  The sealing flange with PTFE oil seal is fitted with a sealing lip support ring. This support ring acts as an assembly sleeve and must not be removed before installation. t  Sealing flange and sender wheel must not be separated or rotated out of position after removal from packaging. t  The sender wheel is held in its installation position by a locating pin on the assembly tool -T10134-. t  The sealing flange and oil seal are one unit and can only be replaced together with the sender wheel. t  The assembly tool -T10134- is held in the correct position relative to the crankshaft by a guide pin which is inserted into a hole in the crankshaft.

Construction of assembly tool -T10134-: A -  Tightening flats B -  Nut C -  Assembly housing D -  Locating pin E -  Hexagon socket-head bolt F -  Guide pin for diesel engines (black handle) G -  Guide pin for petrol engines (red handle)

A - Fitting oil seal with sender wheel onto assembly tool -T10134-: –  Unscrew nut -B- until it is just in front of tightening flats -A- on threaded spindle.

–  Clamp assembly tool -T10134- in a vice on tightening flats -A- of threaded spindle. –  Press the assembly housing -C- downwards so that it lies on the nut -B--arrow-. l  Inner part of assembly device and assembly housing must align (be level) with each other.

–  Remove the securing clip -arrow- from new sealing flange.   Note The sender wheel must not be taken out of the sealing flange or rotated out of position.

l  The locating hole -A- on the sender wheel -C- must align with the marking -B- on the sealing flange.

–  Place the sealing flange (with the front side downwards) on a clean flat surface. –  Press the sealing lip support ring -A- downwards in direction of -arrows- until it lies against the flat surface.

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

–  Place front side of sealing flange on assembly tool -T10134-, so that locating pin -B- can be inserted in hole -A- in sender wheel. l  Ensure the sealing flange lies flat on the assembly tool.

–  Press the sealing flange and sealing lip support ring -B- onto the surface of the assembly tool -T10134- while tightening the 3 knurled screws -A- so that the locating pin will not slip out of the hole in the sender wheel.   Note Ensure that the sender wheel remains fixed on the assembly tool when installing the sealing flange.

B - Installing assembly tool -T10134- with sealing flange on crankshaft flange: l  Crankshaft flange must be free of oil or grease. l  Engine is at „TDC“ position. –  Screw nut -B- to end of threaded spindle. –  Press the threaded spindle of assembly tool -T10134- in direction of -arrow- until the nut -B- lies on the assembly housing -A-. –  Position flat edge of assembly housing towards sealing surface for sump on cylinder block.

–  Secure assembly tool -T10134- to crankshaft flange by screwing hexagon socket head bolts -A- approx. 5 threads into crankshaft flange.

–  Screw two bolts M6×35 mm -item A- into cylinder block to guide sealing flange.

C - Securing assembly tool -T10134- onto crankshaft flange: –  Press the assembly housing -C- by hand in the direction of the -arrow- until the sealing lip support ring -B- lies on the surface of the crankshaft flange -A-. –  Press the guide pin for petrol engines (red handle) -F- into aperture in crankshaft. This ensures that the sender wheel reaches its final installation position.   Note The guide pin for diesel engines (black handle) -D- must not be inserted into threaded hole in crankshaft. –  Tighten the two hexagon socket head bolts on assembly tool hand-tight. –  Screw nut -E- onto threaded spindle by hand until it lies against the assembly housing -C-.

D - Pressing sender wheel onto crankshaft flange with assembly tool -T10134-: –  Tighten nut on assembly tool -T10134- to 35 Nm. l  A small air gap must be present between cylinder block and sealing flange after tightening nut to 35 Nm.

E - Checking installation position of sender wheel on crankshaft: –  Screw nut -E- to end of threaded spindle. –  Remove both bolts -A- from cylinder block. –  Unscrew the three knurled screws -B- from sealing flange. –  Remove hexagon socket head bolts and detach assembly tool -T10134-. –  Detach sealing lip support ring.

–  Apply depth gauge -VAS 6082- to crankshaft flange.

–  Measure distance -a- between crankshaft flange -A- and sender wheel -B-. l  Specification: Distance -a- = 0.5 mm. –  Press sender wheel in further if distance is too small → Anchor. –  If reading matches specification, continue with assembly → Anchor.

F - Pressing sender wheel in further: –  Secure assembly tool -T10134- to crankshaft flange by tightening hexagon socket head bolts -A- hand-tight. –  Slide assembly tool -T10134- onto sealing flange by hand.

–  Screw nut -E- onto threaded spindle by hand until it lies against the assembly housing -C-.

–  Tighten nut on assembly tool -T10134- to 40 Nm. –  Check installation position of sender wheel on crankshaft again → Anchor. –  Tighten nut on assembly tool -T10134- to 45 Nm if distance is too small. –  Check installation position of sender wheel on crankshaft again → Anchor.

Assembling:   Note Renew sealing flange bolts. –  Tighten bolts for sealing flange in diagonal sequence. –  Install engine speed sender -G28- → Rep. gr.28. –  Install sump → Chapter. –  Engage intermediate plate at top of sealing flange -arrow A- and push onto dowel sleeves -arrows B-. –  Tighten plug for „TDC“ drilling → Fig.. –  Install engine speed sender -G28- → Rep. gr.28. –  Install flywheel → Chapter.