Table of contents: Removal and installation the drive… ↓ Removal and installation the front… ↓
1. The installation details of the drive disc and crankshaft seals are shown in the illustrations.
28.1a. Front crankshaft seal installation details:
1 - Flange bolts 7;
2 - Front crankshaft oil seal;
3 - Temperature regulator (thermostat) of the oil cooler;
4 - Bolt, to be replaced, 3 Nm, then tighten to an angle of 90°;
5 - Regulator cover 3;
6, 8, 12 - Sealing ring, subject to replacement;
7 - Front sealing flange, there are options;
9 - Oil temperature sensor No. 2 "G664";
10, 14 - Bolt, 9 Nm;
11 - Sensor holder 9;
13 - Lid;
15, 17 - Gasket, subject to replacement, there are options with/without a metal backing;
16 - Centering pins.
28.1b. Crankshaft Drive Disc and Rear Oil Seal Installation Details:
1 - Drive disk;
2 - Bolt, to be replaced, 60 Nm then tighten to an angle of 90°;
3 - Rotor of the CKP sensor;
4 - Rear crankshaft oil seal;
5 - Centering sleeve of the drive disk;
6 - Crankshaft.
2. Replacing the front oil seal is done in the same way as on 1st generation 3.0 TDI engines (see Section 7), but for the final installation of the oil seal, the T40048/7 sleeve should be used instead of the T40048/4 sleeve. The features of removing/installing the crankshaft pulley are described in Section 27.
3. Replacing the rear oil seal is done in the same way as on 1st generation 3.0 TDI engines (see Section 7), The features of removing/installing the drive disk are described in the subsection below.
Removal and installation the drive disk
4. Remove AT (see chapter 6), or remove the engine and separate it from the AT (see Section 25).
5. Lock the drive disc from turning using tool No. 10-201 (see illustration), unscrew the disk mounting bolts and remove it together with the CKP sensor rotor.
6. Installation is carried out in reverse order. The drive disc can only be installed in one position due to the centering pin. Use new bolts to secure the drive disc. To prevent the disc from turning while tightening the bolts, turn tool #10-201 over.
Removal and installation the front sealing flange
7. Drain the coolant (see Chapter 3).
8. Remove the crankshaft pulley (see Section 27).
9. Disconnect the electrical wiring connector (1 in the illustration) and unhook the EGR cooler switching valve "N345" from the bracket.
28.9. Removing the EGR radiator switching valve.
Disconnect the connector (2) and unscrew the bolt (3). Remove the EGR radiator (see Chapter 4).
10. Remove the drive belt tensioner (see Section 27) and the front coolant pipe (see Chapter 3).
11. Remove the oil filter (see Section 6 of Chapter 1).
12. Unscrew the bolt (1 in the illustration) and pull out the oil dipstick guide tube (see illustration).
28.12. Fastening the oil dipstick guide tube.
13. Remove the bolts (by analogy with illustration 6.7) and remove the coolant pump pulley.
14. Disconnect the connector (1 in the illustration) sensor No. 2 "G664" engine oil temperature.
28.14. Connector (1) of sensor "G664".
15. Disconnect the connectors (2-4 in the illustration), unscrew the bolt (arrow), loosen the clamp (1) and disconnect the coolant hose.
28.15. Connections on the oil filter housing.
16. Remove the plug (8 in illustration 27.1) from the intermediate pulley (10), unscrew the bolt (9) and remove the pulley.
17. Remove the oil cooler temperature regulator (see Section 33).
18. Loosen and remove the bolts in sequence (23-2 in the illustration).
28.18. Sequence (23-2) for unscrewing the front sealing flange fasteners.
Remove the upper coolant hose (arrow) from the sealing flange and remove the flange. Remove the front oil seal from the flange.
19. Clean the mating surfaces from oil and grease. Install the front sealing flange with a new gasket and tighten its mounting bolts in the following order:
28.19. Sequence (1-19) for tightening the front sealing flange fasteners.
- Install the idler roller and tighten its bolt (1 in illustration 28.18) with a force of 23 Nm;
- Tighten the auxiliary steel bolts M6x20 (3,4 and 23 in illustration 28.18) with a force of 9 Nm;
- Install the oil cooler temperature controller together with the cover (see section 33);
- Tighten the bolt (13 in illustration 28.18) to fit;
- Tighten the bolts (1-19 in the illustration) with a force of 3 Nm, and then check this force (it may decrease after the gasket has settled) and tighten the bolts to a 90° angle;
- Remove the auxiliary steel bolts (3,4 and 23 in illustration 28.18) and tighten the standard aluminum bolts instead, first with a force of 3 Nm, and then tighten them to an angle of 90°.
20. Install the new front oil seal (see paragraph 2).