Audi Cars 1999-05

Front Crankshaft Seal

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Removal & Installation



1.8L & 2.0L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. On A4 & 1998-00 Passat models, place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the timing belt.
  8.  
  9. Hold the crankshaft sprocket with tool 3099 and remove the center bolt and sprocket.
  10.  
  11. If the following tools are available,
  12.  
    1. Unscrew the inner part of Oil Seal Extractor 2085, or equivalent, out of the outer part about two turns.
    2.  
    3. Install the socket head bolt into the crankshaft to guide the tool.
    4.  
    5. Apply oil to the Oil Seal Extractor 2085, or equivalent. Apply firm pressure and screw the tool into the oil seal as far as it will go.
    6.  
    7. Loosen the knurled screw and turn the inner part against the crankshaft until the seal is removed.
    8.  
    9. Remove the socket head bolt.
    10.  

  13. If special tools are not available,
  14.  
  15. Wrap a shop rag around the end of the crankshaft, and then use a seal puller to remove the crankshaft oil seal.
  16.  
  17. Remove the shop rag, and then the oil seal.
  18.  



Click image to see an enlarged view

Fig. Tool No. 3099 or equivalent is used to hold the crankshaft toothed gear, allowing removal of the center bolt-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Install the socket head bolt (3083) in the crankshaft to guide the Seal Extractor-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Screw the seal Extractor (2085) into the oil seal while applying pressure-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Install the guide sleeve (3083) on the crankshaft-1.8L and 2.0L engines



Click image to see an enlarged view

Fig. Tighten the socket head bolt to press the seal into place-1.8L and 2.0L engines

To install:

  1. If the following tools are available,
  2.  
    1. Install the guide sleeve from tool 3083 on the end of the crankshaft.
    2.  
    3. Apply oil to the lip of the seal and slide the seal over the guide sleeve.
    4.  
    5. Press the seal in using the thrust sleeve from tool 3083 and a socket head bolt.
    6.  

  3. If special tools are not available,
  4.  
    1. Lightly oil the inner lip of the seal.
    2.  
    3. Install the oil seal over the end of the crankshaft.
    4.  
    5. Using the appropriate seal driver, install the seal flush.
    6.  

  5. Install the crankshaft sprocket. Tighten the crankshaft sprocket bolt to:
  6.  


    Step 1: 66 ft. lbs. (90 Nm)
     
    Step 2: 90° ( 1 / 4 turn)
     

  7. The balance of assembly is in reverse order of removal.
  8.  

1.8L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Place the lock carrier into the service position.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Timing belt
     
    Torque arm mounting bracket
     

  8.  
  9. Hold the crankshaft timing belt gear using tool 3099.
  10.  
  11. Remove or disconnect the following:

    Crankshaft timing belt gear retaining bolt
     
    Crankshaft timing belt gear
     
    Crankshaft oil seal

    Click image to see an enlarged view

    Fig. Tool 3099 is used to hold the crankshaft toothed gear, allowing removal of the center bolt-1.8L engines

     

  12.  

To install:

  1. Install or connect the following:

    New oil seal using a Seal Driver until it is flush. Do NOT oil sealing lip of oil seal.
     
    Timing belt gear. Torque the new bolt to 66 ft. lbs. (90 Nm) plus 1 / 4 (90 degree) turn.
     
    Torque arm mounting bracket. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Timing belt
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function.
  4.  
  5. Check the oil level before starting the engine.
  6.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. On all A6 models, place the lock carrier into the service position.
  4.  
  5. Turn the ignition switch to theOFF
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Crankshaft sprocket
     
    Crankshaft oil seal
     

  8.  

To install:

  1. Install or connect the following:

    New oil seal lubricated with engine oil using a Seal Driver until it is flush
     
    Crankshaft sprocket: Torque to 148 ft. lbs. (200 Nm) plus 90°
     
    Timing belt
     
    Negative battery cable
     

  2.  

2.8L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. On all A4 and A6 models, place the lock carrier into the service position.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Rotate the engine to Top Dead Center (TDC).

    Click image to see an enlarged view

    Fig. The crankshaft is locked in the TDC position by installing tool 3242 through the sealing plug on the left side of the engine block-2.8L engines

  8.  
  9. Remove or disconnect the following:

    Sealing plug from the left side of the engine
     
    Crankshaft by locking it in position using tool 3242
     
    Timing belt
     
    Crankshaft timing belt sprocket from the crankshaft
     
    Seal using a Seal remover
     

  10.  
  11. Clean the running and sealing surfaces.
  12.  

To install:

Click image to see an enlarged view

Fig. Removing the seal using the seal remover-2.8L and 3.0L engines



Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-2.8L and 3.0L engines

  1. Slide the new seal over the Installing Sleeve tool 3202.
  2.  
  3. Install or connect the following:

    New oil seal using a Seal Installer tool 3265 until it is flush
     
    Center crankshaft bolt
     
    Timing belt sprocket. Torque the center crankshaft bolt to 148 ft. lbs. (200 Nm), plus an additional 1 / 2 (180 degree) turn
     
    Timing belt
     
    Accessory drive belt
     

  4.  

2.8L V6 Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Rotate the engine to top dead center, remove the sealing plug from the left side of the engine and lock the crankshaft in position using tool No. 3242, or equivalent.
  8.  
  9. Remove the timing belt.
  10.  
  11. Remove the crankshaft timing belt sprocket from the crankshaft.
  12.  
  13. Remove the seal with a suitable seal remover.
  14.  
  15. Clean the running and sealing surfaces.
  16.  



Click image to see an enlarged view

Fig. Removing the seal using the seal remover-2.8L V6 Engine



Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-2.8L Engine V6

To install:

  1. Lightly oil the inner lip of the seal.
  2.  
  3. Slide the seal over the installing sleeve tool No. 3202, or equivalent.
  4.  
  5. Press the oil seal flush with seal installer tool No. 3265, or equivalent, and the center crankshaft bolt.
  6.  
  7. Install the timing belt sprocket and tighten the center crankshaft bolt to:
  8.  


    Step 1: 148 ft. lbs. (200 Nm)
     
    Step 2: 180° ( 1 / 2 turn)
     

  9. Install the timing belt.
  10.  
  11. Install the accessory drive belt.
  12.  
  13. The balance of assembly is in reverse order of removal.
  14.  

2.8L Vr6 Engine

The pulley/vibration damper is removed to access the front crankshaft seal.

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the wheel well splash shield if it interferes with damper removal.
  4.  
  5. If necessary, remove the lower engine shield.
  6.  
  7. Remove the crankshaft driven accessory drive belt.
  8.  
  9. Counter hold the pulley with Tool No. 3273, or its equivalent.
  10.  
  11. Remove the crankshaft damper bolt.
  12.  
  13. Remove the crankshaft damper assembly.
  14.  
  15. Wrap a shop rag around the end of the crankshaft, and then use a seal puller to remove the crankshaft oil seal.
  16.  
  17. Remove the shop rag, and then the oil seal.
  18.  

To install:

  1. Lightly oil the inner lip of the seal.
  2.  
  3. Install the oil seal over the end of the crankshaft.
  4.  
  5. Using the appropriate seal driver, install the seal flush.
  6.  
  7. Tighten the damper bolt to:
  8.  
    1. Step 1: 74 ft. lbs. (100 Nm)
    2.  
    3. Step 2: 90 ° ( 1 / 4 of a turn)
    4.  

  9. The balance of assembly is in reverse order of removal.
  10.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. On all A4 and A6 models, place the lock carrier into the service position.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Crankshaft sprocket bolt, sprocket and washer
     
    Crankshaft oil seal using Seal Remover tool (3203 and 2085)
     

  8.  
  9. Clean oil seal and crankshaft washer running surfaces.
  10.  

To install:

  1. Install or connect the following:
    WARNING
    2004 models. Do not oil sealing lip or outer edge of sealing ring before pressing in.



    New oil seal lubricated with engine oil using a Seal Driver (3202/1 and 3265) until it is flush
     



    Crankshaft sprocket, using new bolt; torque to 148 ft. lbs. (200 Nm) plus 180 degrees
     
    Timing belt
     
    Negative battery cable
     

  2.  

3.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Before removing ribbed belt, mark direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing belt, ensure it is correctly seated in the pulleys.



    Negative battery cable
     
    Cover over coolant expansion tank
     



    Release tension on belt by screwing an M8 x 40 bolt into bore on tensioning element and remove belt
     
    Center and right sound insulation from under vehicle
     
    Remove bolt for vibration damper using counter hold tool T10059 or equivalent
     
    Unscrew inner section of oil seal extractor 3203 3 turns and lock with knurled screw

    Click image to see an enlarged view

    Fig. Removing the seal using the seal remover-3.2L engine, except TT and A6

     
    Lubricate the threaded head of oil seal extractor, put into position, exert firm pressure and screw into oil seal as far as possible
     
    Loosen the knurled screw and turn inner part against the crankshaft until the oil seal is pulled out
     

  6.  

To install:


NOTE
Do not lubricate the oil seal before installing

  1. Place guide sleeve T10053/1 or equivalent on crankshaft journal
  2.  
  3. Push oil seal carefully over the guide sleeve onto the crankshaft journal as far as possible and remove the guide sleeve
  4.  
  5. Press the oil seal in as far as possible using the old securing bolt for the vibration damper and installation sleeve from 3266 or equivalent
  6.  
  7. Install or connect the following:

    Vibration damper with new securing bolt and tighten to 74 ft. lbs (100 Nm) + 90 degrees (1/4 turn)
     
    Accessory drive belt
     
    Sound insulation
     
    Cover over coolant expansion tank
     
    Negative battery cable
     

  8.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove engine
  4.  
  5. Remove flywheel
  6.  
  7. Remove intake manifold
  8.  
  9. Remove cylinder head cover
  10.  
  11. Remove thermostat housing
  12.  
  13. Remove oil pan
  14.  
  15. Remove or disconnect the following:
    NOTE
    Mark rotation direction of timing chains with a colored arrow before removing. Do not mark the chains using a center punch, notch, or anything similar



    Bolt for timing chain tensioner
     
    Upper timing chain cover. Be careful not to damage the head gasket when removing
     
    Lower timing chain cover. Be careful not to damage the head gasket when removing
     
    Crankshaft oil seal (rear main)
     



    Click image to see an enlarged view

    Fig. Mark timing chain rotation-3.2L engine



    Guide rail
     
    Timing chain from sprocket for intermediate shaft and from behind projection of head gasket
     
    Loosen bolt on intermediate shaft sprocket approximately 1 turn by counter holding the vibration damper with T10059 or equivalent
     
    Loosen valve gear chain tensioner
     
    Remove bolt from intermediate shaft gear and removing chain together with gears
     

  16.  

To install:

  1. Install chain together with intermediate shaft sprocket

    Sprocket can only be installed on intermediate shaft in one position. Turn intermediate shaft slightly if necessary
     

  2.  
  3. Check TDC position of crankshaft

    Ground down tooth of drive chain sprocket must align with main bearing joint (arrow A)
     
    Notch on intermediate shaft sprocket must align with groove on thrust washer for intermediate shaft (arrow B)

    Click image to see an enlarged view

    Fig. Timing gear alignment-3.2L engine

     

  4.  
  5. Install small sprocket on intermediate shaft and install bolt finger tight
  6.  
  7. Release the locking spline in timing chain tensioner with a small screwdriver and press the guide rail against the chain tensioner. Secure in this position

    Click image to see an enlarged view

    Fig. Release locking spline-3.2L engine

  8.  
  9. Tighten intermediate shaft securing bolt by counter holding at vibration damper with T10059
  10.  
  11. Install timing chain as follows:

    Yellow chain link -1- must align with marking -2- on the small chain sprocket for the intermediate shaft
     
    Copper chain link -4- must align with arrows -3- on camshaft adjusters and notches -5- on valve timing housing
     
    There must be 16 chain rollers between intake and exhaust camshaft adjusters

    Click image to see an enlarged view

    Fig. Camshaft timing alignment-3.2L engine

     

  12.  
  13. Install guide rail
  14.  
  15. Remove camshaft plate T10058
    NOTE
    When turning the crankshaft you must press the guide rail firmly against the timing chain to prevent the chain from slipping

  16.  
  17. Turn the crankshaft 2 revolutions in normal direction until timing mark is at TDC
    NOTE
    The marked chain links will now be in an undefined position

  18.  
  19. Insert camshaft plate T10058 in both camshaft grooves. If camshaft plate cannot be inserted, repeat adjustment of valve timing
  20.  
  21. Install lower timing cover. Tighten bolts in diagonal sequence and in stages
  22.  
  23. Install upper timing cover and tighten bolts in following sequence:

    Timing cover to engine block initially to 44 inch lbs (5 Nm)
     
    Bottom of timing cover at head gasket 17 ft. lbs (23 Nm)
     
    Timing cover to engine block to 88 inch lbs (10 Nm)
     

  24.  
  25. Secure timing chain tensioner
  26.  
  27. The remainder of the installation is the reverse of the removal procedure
    NOTE
    Torque Specs



    Pins for guide rail to cylinder block 88 inch lbs (10 Nm)
     
    Chain tensioner to cylinder block 71 inch lbs (8 Nm)
     
    Chain sprockets to intermediate shaft 44 ft. lbs (60 Nm) + 90 degrees (1/4/ turn) Install new bolt
     
    Camshaft adjusters to camshaft 44 ft. lbs (60 Nm) + 90 degrees (1/4/ turn) Install new bolt
     
    Lower timing chain cover to cylinder block 88 inch lbs (10 Nm)
     

  28.  

4.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Timing belt
     
    Timing belt crankshaft sprocket
     
    Oil seal using seal remover 3203
     

  4.  

To install:

  1. Install or connect the following:

    Oil seal over sleeve 3202
     
    Using vibration damper mounting bolt, press in seal with sleeve 3202 until flush
     
    Timing belt crankshaft sprocket
     
    Timing belt
     

  2.  

 
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