Audi Workshop Service and Repair Manuals

Renewing sealing flange (flywheel end) Special tools and workshop equipment required

t  Assembly tool -T10134-

t  Tool insert, AF 22 -V.A.G 1332/12-

t  Depth gauge -VAS 6082- t  Bolt M6x35 (3x) t  Bolt M7x35 (2x)

Pressing out sealing flange with sender wheel l  Gearbox removed. –  Remove dual-mass flywheel → Chapter. –  Detach intermediate plate at sealing flange and dowel sleeves -arrows-. –  Turn the crankshaft to TDC → Chapter.

–  Remove engine speed sender -G28--item 1- using a standard ball head hexagon key. –  Remove sump → Chapter.

–  Unscrew bolts -1 ... 6- for sealing flange.   Note

The sealing flange is pressed off the crankshaft together with the sender wheel. –  To press out, screw in 3 bolts M6x35 -arrows- alternately into sealing flange not more than 1/2 turn at a time. –  Remove sealing flange together with sender wheel. Pressing in sealing flange with sender wheel   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 must always be replaced together with the sender wheel. t  The assembly tool -T10134- is held in its installation position for the crankshaft by a guide pin which is inserted into a hole on the crankshaft.

Construction of assembly tool -T10134- A -  Tightening flats B -  Hexagon 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-: –  Turn hexagon 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 assembly housing -C- downwards so that it lies on hexagon 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 removed from 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.   Note 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 three 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 free of oil and grease. l  Engine is at TDC position. –  Screw hexagon nut -B- to end of threaded spindle. –  Press the threaded spindle of assembly tool -T10134- in direction of -arrow- until the hexagon 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 M7×35 mm -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 diesel engines (black handle) -D- into hole in crankshaft. This ensures that the sender wheel reaches its final installation position.   Note The guide pin for PETROL engines (red handle) -F- MUST NOT be inserted into the threaded hole in the crankshaft. –  Tighten the 2 hexagon socket head bolts on assembly tool finger-tight. –  Screw hexagon 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 hexagon nut of assembly tool -T10134- to 35 Nm.   Note A small air gap must be present between cylinder block and sealing flange after tightening hexagon nut to 35 Nm.

E - Checking installation position of sender wheel on crankshaft: –  Screw hexagon nut -E- to end of threaded spindle. –  Unscrew the 2 bolts -A- out of cylinder block. –  Unscrew the 3 knurled screws -B- from sealing flange. –  Remove assembly tool -T10134-. –  Remove sealing lip support ring.

l  The sender wheel is positioned correctly on the crankshaft if the distance -a- between the crankshaft flange -A- and the sender wheel -B- is 0.5 mm.

–  Apply a depth gauge -VAS 6082- on the crankshaft flange. –  Measure distance -a- between crankshaft flange and sender wheel. If dimension -a- is too small: –  Press in the sender wheel further → Anchor. When dimension -a- is achieved: –  Continue with assembly → Anchor.

F - Pressing sender wheel in further: –  Secure assembly tool -T10134- to crankshaft flange by tightening hexagon socket head bolts finger-tight -items A-. –  Press the assembly tool -T10134- towards the sealing flange by hand.

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

–  Tighten hexagon nut of assembly tool -T10134- to 40 Nm. –  Check installation position of sender wheel on crankshaft again → Anchor. If dimension „a“ is too small again: –  Tighten hexagon nut of assembly tool -T10134- to 45 Nm. –  Check installation position of sender wheel on crankshaft again → Anchor.

Assembling: –  Tighten new securing bolts for sealing flange -1 ... 6- in diagonal sequence.

–  Secure engine speed sender -G28--item 1-. –  Install sump → Chapter.

–  Fit intermediate plate on sealing flange and push onto dowel sleeves -arrows-. –  Install dual-mass flywheel → Chapter. Tightening torques

Component	Nm
Sealing flange to cylinder block	15 1)
Engine speed sender -G28- to cylinder block	5
l  1) Tighten bolts in diagonal sequence