1.4 TSI engine (EA211) · Crankshaft group · Cylinder block, gearbox end

Removing and installing sealing flange on gearbox side

Special tools and workshop equipment required

  • Flared ring spanner tool insert AF 24 - V.A.G 1332/11-
  • Depth gauge - VAS 6082-
  • Assembly tool - T10134-
  • Locating bolt - T10340-
  • Bolt M6x35 (3x)

Procedure

  • Gearbox is removed.
  • Unscrew bolts -arrows- for sealing flange -1-.
  • To press off, screw 3 M6 x 35 bolts -arrows- into sealing flange -1-.
  • Screw bolts alternately into sealing flange not more than 1/2 turn at a time.
  • Remove sealing flange -1- together with sender wheel -2-.

Pressing in sealing flange with sender wheel

Set-up of assembly tool - T10134- :

A - Clamping surface

B - Nut

C - Assembly housing

D - Locating pin

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)

I - Inner part

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.
  • 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.
  • If fitted, remove securing clip -arrow- from new sealing flange.
  • Place sealing flange with front side facing down on a clean level surface.
  • Push sealing lip support ring -1- downwards in -direction of arrow- until it rests against the flat surface.
  • Upper edge of sealing lip support ring -1- and front edge of sealing flange -2- must align -arrows-.
  • 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-.
  • If necessary, rotate sender wheel with support ring so that locating pin and hole align.
  • The sealing flange must rest flat against the assembly tool.
  • Screw knurled screws -H- into sealing flange -1-.
  • Press sealing flange -1- and sealing lip support ring -2- against surface of assembly tool - T10134- whilst tightening knurled screws.
  • This prevents the locating pin from slipping out of the sender wheel hole.
  • When installing sealing flange, ensure that sender wheel remains fixed in assembly tool.

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.
  • 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.
  • 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.
  • To guide sealing flange -1-, screw two M6×35 mm bolts -2- into cylinder block.

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.
  • Tighten the two hexagon socket head bolts of assembly tool hand-tight.
  • Screw nut -B- onto threaded spindle by hand until nut rests against assembly housing -C-.

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-.

Checking sender wheel installation position on crankshaft:

  • 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.
  • 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.
  • Position depth gauge - VAS 6082- on crankshaft flange -2-.
  • Measure distance -a- between crankshaft flange -2- and sender wheel -1-.
  • Specification: dimension -a- = 0.5 mm

Re-pressing sender wheel:

  • Secure assembly tool - T10134- on crankshaft flange -1-.
  • Make sure that locating pin of assembly tool - T10134- is properly seated in sender wheel hole.
  • 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 nut 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 M6×35 mm bolts -2- into cylinder block.

Installing

Torque settings