1.4 MPI engine (EA111) · Crankshaft group · Cylinder block, sealing flange

Renewing crankshaft sealing flange - flywheel end ( assembly tool - T10017- )

Special tools and workshop equipment required

  • Assembly tool - T10017-
  • Torque wrench (5 … 50 Nm) - V.A.G 1331-
  • Insert tool, 24 mm - V.A.G 1332/11-
  • Three hexagon bolts M6 x 35 mm
  • Feeler gauge
  • Depth gauge

2.8.1 Pressing sealing flange with sender wheel off crankshaft

Sequence of operations

  • Remove engine speed sender - G28- -arrow-.
  • Unscrew sealing flange securing bolts.
  • Screw three M6×35 mm bolts into threaded holes -arrows- of sealing flange.
  • Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.

2.8.2 Pressing sealing flange with sender wheel onto crankshaft

A - Hexagon nut

B - Clamping surface

C - Assembly bell housing

D - Hexagon socket head bolt

D - Guide pin

F - Locating pin

2.8.3 A-Assembling sealing flange with sender wheel on assembly appliance - T10017-

  • Screw hexagon nut -A- to shortly before the clamping surface (ground section) -B- on the threaded spindle.
  • Clamp assembly appliance -T10017- in a vice on clamping surface -B- of threaded spindle.
  • Press assembly housing -C- downwards until it lies on hexagon nut -A- -arrow-.
  • Remove securing clip -A- from new sealing flange.

The locating hole -B- on the sender wheel -C- must align with the marking -A- on the sealing flange.

  • Place sealing flange with front side downwards on a clean flat surface.
  • Push sender wheel and 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-.

  • Place sealing flange, with forward side on assembly appliance
    • T10017-, so that locating pin -A- can be inserted in sender wheel hole -B-.
  • Push sender wheel and sealing lip support ring -B- onto surface of assembly appliance whilst tightening the three knurled screws -A-, so that locating pin cannot slip out of sender wheel hole.

2.8.4 B-Assembling appliance -T10017- with sealing flange on crankshaft flange

Conditions

  • Crankshaft flange must be free of oil and grease.
  • Engine positioned at TDC No. 1 cylinder.

Sequence of operations

  • Screw hexagon nut -A- to end of threaded spindle.
  • Press threaded spindle of assembly device in direction of arrow until hexagon nut -A- comes into contact with assembly housing -C-.
  • Align flat side of assembly housing on sump side of crankcase sealing surface.
  • Secure assembly appliance to crankshaft flange with hexagon socket head bolts -A-
  • Screw two M6×35 mm bolts -A- into cylinder block to guide sealing flange.

2.8.5 C-Fitting assembly appliance -T10017- onto crankshaft flange

  • Push assembly hub -A- by hand in direction of arrow until sender wheel and sealing lip support ring -B- contacts crankshaft flange -C-.
  • Hold assembly housing in this position and screw both assembly appliance hexagon socket head bolts hand tight.
  • Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -A-.

2.8.6 D-Pressing sender wheel onto crankshaft flange with assembly appliance - T10017-

  • Tighten assembly appliance hexagon nut with torque wrench
    • V.A.G 1331- and open ring spanner insert -V.A.G 1332/11-.

Specified torque: 35 Nm

2.8.7 E - Checking sender wheel installation position on crankshaft

  • Screw hexagon nut -A- to end of threaded spindle.
  • Remove the two M6×35 mm bolts -B- from cylinder block.
  • Screw the three knurled bolts -C- out of sealing flange.
  • Remove assembly tool - T10017- -D-.

The sender wheel is in the correct installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange

  • A- and sender wheel -B-.
  • Place a vernier caliper against the crankshaft flange -A- (hatched area).
  • Measure the distance -a- between vernier caliper and sender wheel with a feeler gauge -A-.

If dimension -a- is too small:

If dimension -a- is achieved:

  • Tighten the new securing bolts for the sealing flange using alternate and diagonal sequence. Specified torque: 12 Nm

2.8.8 f) Re-pressing sender wheel

  • Push assembly housing -A- by hand to sealing flange -B-.
  • Screw two M6×35 mm bolts -C- into cylinder block to guide sealing flange -B-.
  • Screw hexagon nut -D- onto threaded spindle by hand until it lies on assembly housing -A-.

If dimension -a- is still too small: