135919 Removing And Installing Crankshaft Sealing Ring - Flywheel Side - Turbo
WM 135919 Removing and installing crankshaft sealing ring - flywheel side - Turbo
Tools
Technical values
Preliminary work
NOTICE
Removing and installing flywheel
- Leaks
- Risk of damage to the flywheel and adjacent components
-> Be very careful during removal and installation.
-> Get another person to help because of the weight.
1. Preliminary work for manual transmission:
1.1. Remove manual transmission.
=> 343519 Removing and installing transmission - section on "Removing"
1.2. Remove the clutch.
=> 305019 Removing and installing clutch - section on "Removing"
1.3. Remove dual-mass flywheel.
=> 130019 Removing and installing dual-mass flywheel - Turbo - section on "Removing"
2. Preliminary work for Porsche Double Clutch (PDK):
2.1. Remove Porsche Double Clutch (PDK).
=> 373419 Removing and installing Porsche Double Clutch (PDK) - section on "Removing"
2.2. Remove flywheel.
=> 130019 Removing and installing flywheel - PDK transmission - Turbo - section on "Removing"
Removing crankshaft sealing ring - flywheel side
Information
- Work on delicate engine parts must be carried out conscientiously and precisely.
- Use a suitable tray.
- Absolute cleanliness is essential.
Crankshaft flange sealing ring: -1-
Crankshaft flange sealing ring on flywheel side
WARNING
Caustic fluids
- Danger of chemical burns
-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
1. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone.
1.1. Then, carefully remove metal chips and residual dirt from the crankshaft journal and the crankcase bore using a clean, lint-free cloth soaked in solvent naphtha or acetone.
CAUTION
The crankshaft flange can be damaged if not cleaned correctly.
- Leaks
-> Never use an abrasive or polishing cloth or brushes with metal bristles.
-> Follow cleaning instructions.
2. Remove any corroded spots on the crankshaft flange using a metal-polishing pad only (for example Never Dull, available in car and motor bike accessory stores).
2.1. Then, carefully clean the flange using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.
NOTICE
Drilling work on crankshaft sealing ring
- Risk of engine damage caused by drilling chips
- Risk of damage to the crankcase
- Do not apply pressure while drilling
-> Carefully remove drill chips
-> Drill carefully
3. Drill holes in the crankshaft sealing ring at two directly opposite positions -arrows- using a greased drill bit (dia. 2 - 2.5 mm) and carefully remove drill chips.
Drilling the sealing ring
4. Screw the extractor tip of the tool model G impact puller for sealing rings Nr.168-1 -1- alternately into the bore holes -arrows- and pull the sealing ring out evenly.
Pulling out sealing ring
4.1. Alternatively, screw two tapping screws -arrows- into the bore holes.
Tapping screw with slide hammer no. 168
4.2. Pull sealing ring out alternately using slide hammer kit Nr.168 -1- at the tapping screw.
Information
Visually inspect the crankshaft flange and crankcase bore for damage.
5. Check crankshaft flange and crankcase bore for damage.
6. Clean the camshaft flange again using the metal-polishing pad, if necessary.
6.1. Then, carefully remove grease from the flange and crankcase bore using a clean, lint-free cloth soaked in solvent naphtha or acetone.
6.2. Leave to dry off for at least three minutes to ensure that the vapours of the cleaning agent do not attack the new sealing ring (sealing lip).
Installing crankshaft sealing ring - flywheel side
NOTICE
Incorrect tool
- Risk of damage to components
-> Use prescribed tool.
Component overview of insertion tool
Individual parts of insertion tool
1. Fit the assembly aid 9699/3 into the insertion tool 9699.
1.1. To do this, unscrew the hexagon-head bolt and replace the inserts.
2. Smaller burred spots or damaged areas on the tools can be eliminated with a nail file, then remove with an oilstone, fine abrasive or polishing cloth.
2.1. Remove residual dirt on the tools using solvent naphtha or acetone.
3. Adjust the insertion tool for fitting the supporting sleeve for the sealing ring. Only unscrew the hexagon-head bolt until the groove on the assembly aid 9699/3 is flush with the contact surface of the sleeve -arrow-.
Adjusting insert for sealing ring mounting
CAUTION
Damage to the sealing lip.
- Leaks
-> The crankshaft flange and tools must be perfectly clean and free of grease.
-> The sealing ring must be fitted dry, i.e. no oil, grease or other lubricants can be used.
-> The crankcase bore must not be oiled.
-> The sealing ring can only be positioned on the assembly tool using the supporting sleeve.
-> The new crankshaft sealing ring (PTFE) is supplied on a supporting sleeve as a spare part.
-> Do not remove the sealing ring from the supporting sleeve.
4. Slide the new crankshaft sealing ring -1- onto the assembly aid 9699/3 with the supporting sleeve. Apply pressure on the supporting sleeve only while doing this -2-.
The collar of the supporting sleeve must be facing the crankshaft during assembly.
4.1. Only fit the sealing ring dry.
Sliding PTFE sealing ring with supporting sleeve onto tool
5. Insertion tool 9699 must now be fitted.
5.1. Fit and secure the tool on the crankshaft flange using the two internal M8 cheese head bolts (hexagon socket, a/f 8) -arrows-. The crankshaft flange's dowel pin must fit into the bore of the tool.
Securing insertion tool on crankshaft flange
Information
Insertion tool 9699 must be left in place for about two minutes after fitting the sealing ring so that the sealing lip settles into position on the crankshaft flange.
6. Turn the hexagon-head bolt (a/f 19) clockwise as far as it will go in order to position the crankshaft sealing ring correctly on the crankshaft flange.
6.1. Leave the tool in place for two minutes.
Pulling in sealing ring
7. Remove tool.
7.1. Turn hexagon-head bolt anti-clockwise until the guide screws are still just visible.
7.2. Loosen both hexagon socket head bolts and remove tool.
8. Check that the sealing ring is seated correctly and straight. To do this, measure at four points 90° apart from the crankshaft flange surface to the sealing ring (flat surface).
=> Dimension: 7 mm+/-0.3 mm
9. Leave supporting sleeve on the tool following installation in order to protect the edges of the tool.
9.1. Using a small screwdriver, carefully lever off the sleeve at the bore -arrow- and remove it.
Support ring on insertion tool
Subsequent work
NOTICE
Removing and installing flywheel
- Leaks
- Risk of damage to the flywheel and adjacent components
-> Be very careful during removal and installation.
-> Get another person to help because of the weight.
1. Subsequent work for manual transmission:
1.1. Install dual-mass flywheel.
=> 130019 Removing and installing dual-mass flywheel - Turbo - section on "Installing"
1.2. Install the clutch.
=> 305019 Removing and installing clutch - section on "Installing"
1.3. Install manual transmission.
=> 343519 Removing and installing transmission - section on "Installing"
2. Subsequent work for Porsche Double Clutch (PDK):
2.1. Install flywheel.
=> 130019 Removing and installing flywheel - PDK transmission - Turbo - section on "Installing"
2.2. Install Porsche Double Clutch (PDK).
=> 373419 Removing and installing Porsche Double Clutch (PDK) - section on "Installing"