Volkswagen Golf Service & Repair Manual: Removing and installing sealing flange on gearbox side
| Special tools and workshop equipment
required |
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| Flared ring spanner tool insert AF 24 -V.A.G 1332/11- |
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| – |
Remove flywheel
→ Chapter. |
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| – |
Remove intermediate plate -1-
from dowel sleeves -arrows A-. |
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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: |
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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. |
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Turn crankshaft in direction of engine rotation to “BDC” for
no. 1 cylinder. |
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| – |
Turn crankshaft further in direction of engine rotation,
until screwdriver has moved 35 mm upwards in
-direction of arrow-. |
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Unscrew plug for “TDC” hole in cylinder block
→ Fig.. |
| – |
Unscrew plug for “TDC” hole in cylinder block. |
| If locking pin -T10340- cannot be screwed in as far as stop,
this indicates that crankshaft is not in the correct position! |
| In this case, proceed as follows: |
| Turn crankshaft 90° in direction of engine rotation. |
| Screw locking pin -T10340- into cylinder block as far as
stop and tighten to 30 Nm. |
| 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 Nm. |
| – |
Rotate crankshaft in normal direction of rotation as far as
stop. |
| The locking pin now rests against the crank web. |
 Note
| 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“. |
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Remove engine speed sender -G28-
→ Chapter. |
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Unscrew bolts -arrows- for
sealing flange -1-. |
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| The sealing flange with a PTFE seal is equipped with a
sealing lip support ring -2-. This
support ring serves as a fitting sleeve and must not be removed
prior to installation. |
| Sealing flange and sender wheel -1-
must not be separated or turned after removal from packaging. |
| The sender wheel -1- is held in
its installation position on the locating pin of the assembly
tool -T10134-
→ Anchor. |
| Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel. |
| The assembly tool -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft
→ Anchor. |
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| Components of assembly tool -T10134-: |
| E - |
Hexagon socket head bolt (qty. 2) |
| F - |
Guide pin for petrol engines (red knob) |
| G - |
Guide pin for diesel engines (black knob) |
| H - |
Knurled screws (qty. 3) |
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| 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. |
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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. |
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If fitted, remove securing clip
-arrow- from new sealing flange. |
Note
| Do not take the sender wheel out of the sealing flange or
rotate it out of position. |
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Place sealing flange with front side facing down on a clean
level surface. |
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Push sealing lip support ring -1-
downwards in -direction of arrow-
until it rests against level surface. |
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| Upper edge of sealing lip support ring
-1- and front edge of sealing flange
-2- must align
-arrows-. |
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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. |
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Screw knurled screws -H- into
sealing flange -1-. |
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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. |
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| 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. |
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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. |
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To guide sealing flange -1-,
screw two M6Ч35 mm bolts -2- into
cylinder block. |
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| 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. |
Note
| The guide pin for diesel engines (black knob) must not be
inserted in threaded hole of crankshaft. |
| – |
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-. |
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| Pressing sender wheel onto crankshaft flange using assembly
tool -T10134-: |
| – |
Tighten nut -B- of assembly
tool -T10134- to 35 Nm. |
| After the nut has been tightened to 35 Nm, a small air gap
must still be present between cylinder block and sealing flange
-1-. |
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| Checking sender wheel installation position on crankshaft: |
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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. |
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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. |
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Position depth gauge -VAS 6082- on crankshaft flange
-2-. |
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Measure distance -a- between
crankshaft flange -2- and sender
wheel -1-. |
| Specification: dimension -a- =
0.5 mm |
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If specification is not achieved, press sender wheel further
in
→ Anchor. |
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If specification is achieved, proceed with subsequent work
steps
→ Anchor. |
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| Re-pressing sender wheel: |
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Secure assembly tool -T10134- on crankshaft flange
-1-. |
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Make sure that locating pin of assembly tool -T10134- is
properly seated in sender wheel hole. |
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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. |
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Tighten nut -B- of assembly
tool -T10134- to 40 Nm. |
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Check sender wheel installation position on the crankshaft
again
→ Anchor. |
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If the specification is not achieved, tighten nut of
assembly tool -T10134- to 45 Nm. |
| – |
Check sender wheel installation position on the crankshaft
again
→ Anchor. |
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Tighten bolts for sealing flange
→ Fig.. |
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Install lower part of sump
→ Chapter „Removing and installing lower part of sump“. |
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Install upper part of sump
→ Chapter „Removing and installing upper part of sump“. |
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Install intermediate plate
→ Fig.. |
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Install flywheel
→ Chapter. |
| → Fig. „“Sealing flange on gearbox side - specified torque and
tightening sequence”“ |
| → 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“ |
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