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 –  Vehicles with auxiliary 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. Leave rear noise insulation in position. –  Remove bumper cover (front) → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove toothed belt: t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Chapter. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Chapter. t  Engine codes BKE, BPW, BRB, BRC → Chapter. Vehicles up to 05.2003: –  Unscrew bolts -arrows- and remove torque reaction support from sump.

All vehicles: –  Remove crankshaft sprocket; use counterhold tool -3415- to lock sprocket in place.

–  Before fitting oil seal extractor, fully screw in centre bolt for sprocket into crankshaft.

–  Unscrew inner section of oil seal extractor -3203- 8 turns out of outer section and lock with knurled screw. –  Lubricate threaded head of oil seal extractor, place it in position and screw it into oil seal as far as possible (applying firm pressure). –  Loosen knurled screw and turn inner part against crankshaft until the oil seal is pulled out. –  Clamp flats of oil seal extractor in vice. –  Remove oil seal with pliers. –  Clean running surface and sealing surface.   Note

Do not lubricate sealing lip and outer rim of oil seal before pressing in. –  Place guide sleeve -T10053/1- onto crankshaft journal.

–  Slide oil seal over guide sleeve. –  Press in oil seal until flush using the centre bolt and assembly tool -T10053-.

–  Renew centre bolt for toothed belt sprocket. l  Contact surface between toothed belt sprocket and crankshaft must be free of oil. l  Do not lubricate bolt for crankshaft sprocket. –  Install crankshaft sprocket. To do this, counterhold sprocket with counterhold tool -3415-. The remaining installation steps are carried out in the reverse sequence. –  Fit toothed belt (adjust valve timing): t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. t  Engine codes BKE, BPW, BRB, BRC → Anchor. –  Install vibration damper: vehicles up to 05.2003 → Anchor, vehicles from 06.2003 onwards → Anchor. –  Install viscous fan → Chapter. –  Install poly V-belt: vehicles up to 05.2003 → Anchor, vehicles from 06.2003 onwards → Anchor. –  Install lock carrier with attachments → Rep. Gr.50.

Vehicles up to 05.2003 –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. All vehicles: –  Install bumper cover (front) → Rep. Gr.63. Tightening torques

Component	Nm
Toothed belt sprocket to crankshaft	120 + 90° 1)
Stop for torque reaction support	28
l  1) Renew bolt.