Volkswagen Cars 2000-05

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.  

2.8L (Atq/Bdf) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Timing belt.
     
    Timing belt sprocket from the crankshaft.
     
    Seal with Seal Remover 3203 or equivalent.
     

  4.  
  5. Clean the running and sealing surfaces.
  6.  

To install:

Click image to see an enlarged view

Fig. Removing the seal using Seal Remover 3203-6-cylinder engines



Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-6-cylinder engines

  1. Slide the seal over the Installing Sleeve 3202 or equivalent.
  2.  
  3. Press the oil seal flush with Seal Installer 3265, or equivalent, and the center crankshaft bolt.
  4.  
  5. Install the timing belt sprocket. Center crankshaft bolt: 671 inch lbs. (90 Nm) plus 1 / 4 turn.
  6.  
  7. Install the timing belt and all remaining components.
  8.  

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.  

4-Cylinder Engines


Click image to see an enlarged view

Fig. Install the socket head bolt (3083) in the crankshaft to guide the Seal Extractor-4-cylinder engines



Click image to see an enlarged view

Fig. Screw the Seal Extractor (2085) into the oil seal while applying pressure-4-cylinder engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Accessory drive belts.
     
    Timing belt.
     

  4.  
  5. Hold the crankshaft sprocket with tool 3099 and remove the center bolt and sprocket.
  6.  
  7. Unscrew the inner part of Oil Seal Extractor 2085 or equivalent out of the outer part about 2 turns.
  8.  
  9. Install the socket head bolt into the crankshaft to guide the tool.
  10.  
  11. Apply oil to Oil Seal Extractor 2085 or equivalent. Apply firm pressure and screw the tool into the oil seal as far as it will go.
  12.  
  13. Loosen the knurled screw and turn the inner part against the crankshaft until the seal is removed.
  14.  
  15. Remove the socket head bolt.
  16.  

To install:

  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.  
  7. Remove the tools and install the crankshaft sprocket. Bolt: 66 ft. lbs. (90 Nm) plus14
  8.  
  9. Install or connect:

    Timing belt.
     
    Accessory drive belt and remaining components.
     
    Negative battery cable.
     

  10.  


    Click image to see an enlarged view

    Fig. Install the guide sleeve (3083) on the crankshaft-4-cylinder engines



    Click image to see an enlarged view

    Fig. Tighten the socket head bolt to press the seal into place-4-cylinder engines


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Accessory drive belts.
     
    Timing belt.
     

  4.  
  5. Hold the crankshaft sprocket with tool 3099 and remove the center bolt and sprocket.
  6.  
  7. Unscrew the inner part of Oil Seal Extractor 2085 or equivalent out of the outer part about 2 turns.
  8.  
  9. Install the socket head bolt into the crankshaft to guide the tool.
  10.  
  11. Apply oil to Oil Seal Extractor 2085 or equivalent. Apply firm pressure and screw the tool into the oil seal as far as it will go.
  12.  
  13. Loosen the knurled screw and turn the inner part against the crankshaft until the seal is removed.
  14.  
  15. Remove the socket head bolt.

    Click image to see an enlarged view

    Fig. Install the socket head bolt (3083) in the crankshaft to guide the Seal Extractor-4-cylinder engines



    Click image to see an enlarged view

    Fig. Screw the Seal Extractor (2085) into the oil seal while applying pressure-4-cylinder engines

  16.  

To install:

  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.  
  7. Remove the tools and install the crankshaft sprocket. Bolt: 671 inch lbs. (90 Nm) plus 1 / 4 turn.
  8.  
  9. Install or connect:

    Timing belt.
     
    Accessory drive belt and remaining components.
     
    Negative battery cable.

    Click image to see an enlarged view

    Fig. Install the guide sleeve (3083) on the crankshaft-4-cylinder engines



    Click image to see an enlarged view

    Fig. Tighten the socket head bolt to press the seal into place-4-cylinder engines

     

  10.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove drive belt for A/C compressor.
  4.  
  5. Lock crankshaft in place and remove belt pulley from crankshaft.
  6.  
  7. Remove tensioning element.
  8.  
  9. Remove bolts and begin pressing off sealing flange at alignment sleeves using a suitable screwdriver.
  10.  
  11. Use removal wedge 3409 to support screwdriver so that sealing surface of cylinder block will not be damaged.
    NOTE
    The sealing flange will be damaged when removing.

  12.  
  13. Press off sealing flange completely.
    NOTE
    After removing sealing flange, clean trim removal wedge 3409 which is intended for the removal of interior equipment parts.

  14.  

To install:

  1. While wearing safety goggles, remove sealant residue from the cylinder block, e.g. with a rotating plastic brush. Make sure that no sealant residue enters the engine.
  2.  
  3. Clean sealing surfaces of cylinder block and end of crankshaft; they must be free of oil and grease.
    NOTE
    Do not oil or grease the sealing lip of the sealing flange! To prevent the sealing lip of the sealing flange from inverting, follow the work steps exactly.

  4.  
  5. Spread sealing lip of sealing flange, as shown, with assembly sleeve T03004. The surface A is the outer side.

    Click image to see an enlarged view

    Fig. Spread sealing lip of sealing flange with assembly sleeve T03004-5-cylinder engines



    Click image to see an enlarged view

    Fig. After a short while, remove assembly sleeve T03004, rotate it 180° and insert it into seal-5-cylinder engines

  6.  
  7. After a short while, remove assembly sleeve T03004, rotate it 180° and insert it into seal. The assembly sleeve T03004 must protrude approx. 0.12 inch (3mm) on the inner side B . The surface A is the outer side. The surface B is the inner side (sealing surface).
  8.  
  9. Cut tube nozzle at front marking (nozzle: approx. 0.08 inch (2mm) diameter).
  10.  
  11. Apply a 0.10-0.12 inch (2.5-3mm) width x 0.04 inch (1mm) height bead of sealant into the outer groove of the mating surface of the sealing flange.
    NOTE
    Install the crankshaft sealing flange within 5 minutes of applying the sealant.

  12.  
  13. Set sealing flange with assembly sleeve T03004 onto end of crankshaft and press evenly onto cylinder block.
  14.  
  15. Install and tighten the sealing flange-to-cylinder block bolts, evenly in a diagonal sequence, to 7 ft. lbs. (10 Nm).
  16.  
  17. Further assembly is performed in reverse order of removal. Note the following:


    1. Remove locking pin T40069 from rear of cylinder block and screw in locking bolt (30 Nm).
    2.  
    3. Tighten the belt pulley-to-crankshaft bolts to 48 ft. lbs. (70 Nm).
    4.  
    5. Tighten the tensioning element-to-accessory assembly bracket fasteners to 24 ft. lbs. (35 Nm).
    6.  
    7. Tighten the locking bolt-to-rear of cylinder block to 21 ft. lbs. (30 Nm).
    8.  

  18.  

6-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Timing belt.
     
    Timing belt sprocket from the crankshaft.
     
    Seal with Seal Remover 3203 or equivalent.
     

  4.  
  5. Clean the running and sealing surfaces.
  6.  

To install:



Click image to see an enlarged view

Fig. Removing the seal using Seal Remover 3203-6-cylinder engines



Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-6-cylinder engines

  1. Slide the seal over the Installing Sleeve 3202 or equivalent.
  2.  
  3. Press the oil seal flush with Seal Installer 3265, or equivalent, and the center crankshaft bolt.
  4.  
  5. Install the timing belt sprocket. Center crankshaft bolt: 66 ft. lbs. (90 Nm) plus14
  6.  
  7. Install the timing belt and all remaining components.
  8.  

8-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Timing belt.
     
    Timing belt sprocket from the crankshaft.
     
    Pry out seal with Remover lever 681 or equivalent.
     

  4.  
  5. Clean the running and sealing surfaces.
  6.  

To install:



Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-8-cylinder engines

  1. Slide the seal over the Installing Sleeve 10124/1 or equivalent.
  2.  
  3. Press the oil seal flush with Seal Installer 10124/2, or equivalent, and the center crankshaft bolt.
  4.  
  5. Install the timing belt sprocket. Center crankshaft bolt: 74 ft. lbs. (100 Nm) plus14
  6.  
  7. Install the timing belt and all remaining components.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Timing belt.
     
    Timing belt sprocket from the crankshaft.
     
    Pry out seal with Remover lever 681 or equivalent.
     

  4.  
  5. Clean the running and sealing surfaces.
  6.  

To install:

Click image to see an enlarged view

Fig. Installing the seal using the seal installer and the crankshaft center bolt-8-cylinder engines

  1. Slide the seal over the Installing Sleeve 10124/1 or equivalent.
  2.  
  3. Press the oil seal flush with Seal Installer 10124/2, or equivalent, and the center crankshaft bolt.
  4.  
  5. Install the timing belt sprocket. Center crankshaft bolt: 74 ft. lbs. (100 Nm) plus 1 / 4 turn.
  6.  
  7. Install the timing belt and all remaining components.
  8.  

 
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