Front Sealing Flange, Removing and Installing
Front sealing flange, removing and installing
Special tools and equipment
^ Clamping bolt 3242
^ Thrust piece T40007
^ Electric drill with plastic brush attachment
^ Protective goggles
^ Silicone sealant:, Refer to Parts Supplier
Removing
- Remove lock carrier, Refer to Body and Frame
- Unplug electrical connector -5- at Charge Air Pressure Sensor -G31 -.
- Loosen hose clamps -3- and -4-.
- Pull off hoses at air recirculation valves.
- Remove bolts -1- and -2- detach air intake pipe.
- Remove ribbed belt.
- Unbolt ribbed belt tensioning roller (arrow).
- Remove cover for bottom idler wheel.
- Remove bottom idler wheel for ribbed belt (arrow).
- Remove upper toothed belt guard on left and right.
WARNING: Engine must only be turned over at crankshaft in direction of engine rotation (clockwise).
- Set crankshaft to markings for TDC of No. 5 cylinder by turning central bolt on crankshaft sprocket in direction of rotation.
^ Notch -B- aligned with marking -A-.
Note: Turn over engine at central bolt on crankshaft.
- Check position of camshafts:
^ Larger holes (arrows) in securing plates on camshaft sprockets should point inwards.
- If this is not the case, turn crankshaft one complete revolution.
- Unscrew nuts -1- to -4- for left and right stabilizer bar mountings.
- Remove left bracket for noise insulation (arrows).
- Unscrew bolts -1-and -2-.
- Loosen hose clamps (arrows) and detach left air pipe.
- Unscrew plug -arrow- for TDC marking from upper section of sump.
Note: There is a TDC drilling in crankshaft directly behind plug (it is possible to feel the hole).
WARNING: -Risk of injury- do not turn crankshaft while feeling for TDC drilling with a finger.
- Screw clamping bolt 3242 into hole where plug has been removed.
- Loosen 8 securing bolts -1- and remove vibration damper on crankshaft.
- Remove top idler wheel for ribbed belt (arrows).
- Remove center toothed belt guard.
- Remove securing bolts -1- to -3- and remove torque reaction support.
- Remove bracket for torque reaction support (arrows).
- Remove toothed belt.
- Remove central bolt -2- for crankshaft sprocket -1-.
- Remove toothed belt sprocket.
- Unbolt eccentric wheel -3-, tensioning lever with tensioning roller -2- and belt tensioner -1-.
- Unscrew oil spray jet -2-.
- Unscrew bolts -1-.
- Remove lower section of sump.
- Unscrew bolts -1-and -2-.
- Pull off front sealing flange.
- Drive out oil seal with flange removed.
- Mark front side of thrust ring (arrow) with a water-resistant felt-tip pen.
- Pull thrust ring off crankshaft.
Note: Illustrated with sealing flange installed.
Installing
Note: Always install new gaskets, seals and O-rings.
- Put a rag over open part of sump.
- Carefully remove remaining sealant on upper section of sump.
- 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.
- Cut off nozzle of tube at front marking (nozzle diameter approximately 1 mm).
- Place new gasket -1- on cylinder block.
- Apply a thin bead of silicone sealant at joints between cylinder block and upper section of sump on each side (arrows).
- Apply a thin coat of silicone sealant to lower sealing surface of sealing flange -hatched area-.
Note: Sealing flange must be installed within 5 minutes after applying silicone sealant.
- Carefully push sealing flange onto dowel pins on cylinder block.
- Tighten bolts -1- and oil spray jet -2-.
- Tighten bolts -1-and -2-.
- Install lower section of sump.
- Do not lubricate sealing lip or outer circumference of seal before pressing in.
- Press in seal using thrust piece T40007 and center bolt.
- Turn thrust ring front to back and install on crankshaft.
Note:
^ The reason for turning thrust ring is to allow new oil seal to run on new sealing surface.
^ The previously marked side of thrust ring should now face toward engine.
- Install crankshaft sprocket -1- with new center bolt -2-.
Note:
^ Contact surface between toothed belt sprocket and crankshaft must be free of oil.
^ Do not oil bolt for crankshaft sprocket.
^ Watch washer under tensioning lever.
Remaining installation steps are carried out in reverse sequence - note following points-.
Note:
^ Secure all hose connections with correct hose clamps (same as original equipment) See parts catalog
^ Remove any traces of oil or grease on hose connections and hoses for charge air system before installing. Do not apply lubricant.
- Install toothed belt (adjust valve timing), Refer to Engine Service and Repair.
- Installing lock carrier with attachments-.
- Install front bumper
- Install air filter housing.
- Top off coolant.
- Adjust headlights-.
Tightening torques