Audi Workshop Service and Repair Manuals

Renewing crankshaft oil seal (pulley end)

Special tools and workshop equipment required

t	Oil seal extractor -3203-

t	Counterhold tool -3415-

t	Assembly tool -T10053-

Procedure –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50. –  Remove toothed belt: t  Vehicles to 04.2003 → Chapter. t  Vehicles from 05.2003 to 05.2004 → Chapter. t  Vehicles from 06.2004 → Chapter.

–  Remove crankshaft sprocket; use counterhold -3415- to lock sprocket in place.

–  To guide oil seal extractor, screw central bolt into crankshaft onto stop by hand. –  Unscrew inner part of oil seal extractor -3203- 9 turns (approx. 20 mm) from the outer part and lock in position with the knurled screw.

–  Lubricate threaded head of oil seal extractor -3203-, place it in position and screw it into oil seal as far as possible (apply firm pressure). –  Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out. –  Clamp flats of oil seal extractor in vice. –  Remove oil seal with pliers.

–  Clean running surface and sealing surface. –  Remove oil residue from crankshaft journal with a clean cloth. –  Place guide sleeve -T10053/1- onto crankshaft journal. –  Slide oil seal over guide sleeve onto crankshaft journal.

–  Press in oil seal flush using the centre bolt of toothed belt sprocket and press sleeve from assembly tool -T10053-.

–  Renew centre bolt for toothed belt sprocket. –  Install crankshaft sprocket; use counterhold tool -3415- to lock sprocket in place.   Note t  Contact surface between toothed belt sprocket and crankshaft must be free of oil. t  Do not lubricate bolt for crankshaft sprocket. –  Fit toothed belt (adjust valve timing): t  Vehicles to 04.2003 → Anchor. t  Vehicles from 05.2003 to 05.2004 → Anchor. t  Vehicles from 06.2004 → Anchor. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. Tightening torque

Component	Nm
Toothed belt sprocket to crankshaft	90 + 90° 1)2)
l  1) Renew bolts. l  2) 90° = one quarter turn.