1.2 TDI CR engine (EA189) · Crankshaft group · Cylinder block, gearbox end

Removing and installing sealing flange on gearbox side

⇒ 2.3.1 Pressing out sealing flange with sender wheel

⇒ 2.3.2 Pressing in sealing flange with sender wheel

⇒ 2.3.3 A - Assemble seal with sender wheel on assembly tool T10134.

⇒ 2.3.4 B - Fitting assembly tool T10134 with sealing flange to crankshaft flange

⇒ 2.3.5 C - Bolting assembly tool T10134 onto crankshaft flange

⇒ 2.3.6 D - Pressing sender wheel onto crankshaft flange using assembly tool T10134

⇒ 2.3.7 E - Checking sender wheel installation position on crankshaft

⇒ 2.3.8 f) Re-pressing sender wheel

Special tools and workshop equipment required

  • Assembly tool - T10134-
  • Torque wrench - V.A.G 1331-
  • Tool insert 24 mm - V.A.G 1332/11-
  • Depth gauge - VAS 6082-
  • 3 hexagon bolts M6 x 35 mm
  • 2 hexagon bolts M7 x 35 mm

2.3.1 Pressing out sealing flange with sender wheel

  • Removing gearbox ⇒ Rep. gr. 34; Removing and installing gearbox.
  • Remove flywheel.
  • Detach intermediate plate at sealing flange and dowel pins -arrows-.
  • Remove bolts for sealing flange -1 … 6-.
  • 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 with sender wheel.

2.3.2 Pressing in sealing flange with sender wheel

Assembly tool - T10134-

A - Clamping surface

B - Hexagon nut

C - Assembly housing

D - Locating pin

E - Hexagon socket head bolt

F - Guide pin for diesel engines (black knob)

G - Guide pin for petrol engines (red knob)

2.3.3 A - Assemble seal with sender wheel on assembly tool - T10134-.

  • Screw on hexagon nut -B- until just before it touches the clamping surface -A- of the threaded spindle.
  • Clamp assembly tool - T10134- in a vice on clamping surface
    • A- of threaded spindle.
  • Press assembly housing -C- downwards until it lies on hexagon nut -B- -arrow-.
  • Remove securing clip -arrow- from new sealing flange.
  • Locating hole -A- on sender wheel -C- must align with marking
    • B- on sealing flange.
  • Place sealing flange with front side facing down on a clean, level surface.
  • Push sealing lip support ring -A- downwards in direction of arrow until it lies on flat surface.
  • Upper edge of sender wheel and front edge of sealing flange must align -arrows-.
  • Fit sealing flange with front side facing downwards onto assembly tool - T10134- so that locating pin -B- can be inserted in sender wheel hole -A-.
  • Press sealing flange and sealing lip support ring -B- against surface of assembly tool - T10134- whilst tightening the 3 knurled screws -A-.

This prevents locating pin from slipping out of sender wheel hole.

2.3.4 B - Fitting assembly tool - T10134- with sealing flange to crankshaft flange

  • Crankshaft flange must be free of oil and grease.
  • Engine positioned at TDC of cylinder no. 1.
  • Screw hexagon nuts -B- to end of threaded spindle.
  • Press threaded spindles of assembly tool - T10134- in direction of arrow, until hexagon nut -B- lies against assembly housing -A-.
  • Align flat side of assembly housing to crankcase's sealing surface on the oil sump side.
  • Secure assembly tool - T10134- to crankshaft flange with hexagon socket head bolts -A-.
  • To guide sealing flange into cylinder block, screw in 2 M7 × 35 mm bolts -A-.

2.3.5 C - Bolting assembly tool - T10134- onto crankshaft flange

  • Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- touches crankshaft flange -A-.
  • Push guide pin for diesel engines (black knob) -D- into hole in crankshaft. This ensures that the sender wheel reaches its final installation position.
  • Tighten the two hexagon socket head bolts of the assembly tool hand-tight.
  • Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

2.3.6 D - Pressing sender wheel onto crankshaft flange using assembly tool - T10134-

  • Tighten hexagon nut of assembly tool - T10134- with torque wrench - V.A.G 1331- and tool insert - V.A.G 1332/11- to 35 Nm.

2.3.7 E - Checking sender wheel installation position on crankshaft

  • Screw hexagon nut -E- to end of threaded spindle.
  • Unscrew the two bolts -A- from the cylinder block.
  • Unscrew the three knurled screws -B- out of sealing flange.
  • Remove assembly tool - T10134-.
  • Remove sealing lip support ring.
  • The sender wheel is exactly in the installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange -A- and sender wheel -B-.
  • Place caliper gauge on crankshaft flange.
  • Measure distance between crankshaft flange -A- and sender wheel -B-.
  • Specification: dimension -a- = 0.5 mm

If dimension -a- is attained:

  • Tighten bolts for sealing flange.
  • Tighten bolts in 2 stages as follows:
Stag eBoltsSpecified torque
1)-1 … 6-Screw in by hand as far as stop
2)-1 … 6-In diagonal sequence and in stages; final torque 15 Nm

2.3.8 f) Re-pressing sender wheel

  • Secure assembly tool - T10134- to crankshaft flange with hexagon socket head bolts -A-.
  • Tighten the two hexagon socket head bolts hand-tight.
  • Push assembly tool - T10134- against the sealing flange by hand.
  • Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

If dimension -a- is still too small: