Removal and installation of the flywheel, replacement of the crankshaft oil seal

If oil is leaking from the flywheel side, check the crankshaft oil seal and replace if necessary.

Attention: Since November 1985, modified crankshaft bearing shells have been installed. In this regard, seals and spacers have also been changed.

Oil seal / Spacer washers from November 1985

Removing

Remove engine.

Remove clutch.



Fix the flywheel with the special tool VAG or unscrew the 5 bolts with a socket head bolt wrench and remove the flywheel.


If necessary, remove the crankshaft oil seal with a screwdriver and replace.

Attention: Note the number of spacer washers for adjusting the crankshaft axial play, keep the washers.

If replacement of the needle bearing is required, remove the needle bearing using an appropriate puller (with an inner diameter of 14.5-18.5 mm). First remove the distance, felt and sealing ring from the crankshaft.

After washing the needle bearing in gasoline, lubricate it with universal grease.

Installation

If the needle bearing was removed, install it.



When installing a needle bearing on the crankshaft, make sure that the inscription on the bearing can be read in the installed position. Carefully press in the needle bearing with tool VW 207 or a suitable pin against the outer edge of the bearing.


Insert a new O-ring into the flywheel.

Lubricate the felt ring and insert into the crankshaft together with the spacer ring. Wipe off excess oil.

Check crankshaft end play.

Insert the 3 spacer washers required.



Lightly lubricate the oil seal with engine oil. Screw the tool VW 191 into the crankshaft and tighten the guide with the oil seal on it. If there is no special tool, carefully drive the stuffing box with a pipe of the appropriate diameter.

Insert a new rubber seal into the flywheel.

Place the flywheel on the crankshaft, paying attention to the installation of the pin and tighten the bolts to a torque of 30 Nm with a 1/4 turn adjustment (90°).

Attention: Be sure to install new bolts covered with sealing compound.

Install clutch.

Install the engine.