Front Sealing Flange, Removing and Installing

Special tools, testers and auxiliary items required:
^ Electric drill with plastic brush attachment
^ Silicone sealant D 176 404 A2

Removing
^ Remove ribbed belt and tensioning element, Refer to, Drive belt, Service and Repair.
^ Remove toothed belt, removing and installing.
^ Remove lower air duct, item 11, Refer to Powertrain Management.





^ Remove crankshaft sprocket. To do this counter - hold sprocket with 3099.
^ When fitting retainer, place 2 washers between sprocket and retainer.

Notes: On some engines there is a rib on the sump flange which prevents retainer 3099 from being attached as shown. In this case proceed as follows:
^ Unscrew bolts from retainer, and screw back in from the reverse side.
^ Knock the fitted pins in the square bars downward until they are flush with the top surface of the bars.
^ Bolt the retainer to the crankshaft (fit 2 washers between sprocket and retainer),

^ Drain off engine oil.
^ Remove oil pump.
^ Unbolt front sealing flange.
^ Remove sealing flange: release by tapping lightly with a rubber hammer if necessary.
^ Remove sealant remaining on cylinder block with flat scraper.





^ Remove sealant remaining on sealing flange (with rotating plastic brush or similar).

WARNING: Wear eye protection

^ Clean sealing surfaces: they must be free of oil and grease.

Installing

Notes: The sealing flange must be installed within 5 minutes after applying silicone sealant.





^ Cut off nozzle of tube at front marking (nozzle diameter approximately 3 mm).
^ The sealant should applied in a bead 2 - 3 mm wide - arrows -.

Notes: The bead of sealant must not be thicker than 3 mm, otherwise excess sealant can enter the sump and obstruct the filter screen in the oil intake pipe.





^ Apply the bead of silicone sealant onto the clean sealing surfaces of the sealing flange, as illustrated. Fit the sealing flange immediately, and tighten all bolts lightly.





Notes: To fit sealing flange with the oil seal already installed, use guide sleeve from 2080A.

^ Tighten bolts on sealing flange in diagonal sequence.
^ Install oil sump.

Notes: After installing, the sealant must be allowed to dry for about 30 minutes before putting in engine oil.

^ Install crankshaft sprocket.

Notes: Replace central bolt for sprocket.

^ Install toothed belt (adjust valve timing).
^ Install ribbed belt and tensioning element.

Tightening torques
^ Sealing flange to cylinder block: 15 Nm
^ Toothed belt sprocket to crankshaft: 90 Nm + additional 90°

Notes: 90° = 114