Engine: Testing and Inspection
Checking crankcase for leaks - joint on flywheel side
Preliminary work
Danger
Vehicle can fall down
^ Risk of squashing or crushing
^ Risk of damage to the vehicle
-> Do not place any solid objects under the raised vehicle.
-> Ensure that the lifting platform is prevented from lowering.
-> Remove solid objects before lowering the vehicle.
-> Raise the vehicle only at the take-up points provided.
Warning
Objects or loads falling down
^ Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Warning
Objects or loads falling down
^ Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Manual transmission vehicles:
- Remove transmission. Retaining device 9624/2 must be used to support the engine.
Caution
Clutch pressure plate not loosened and tightened correctly.
^ Pressure plate can be deformed.
-> Always loosen and tighten screws crosswise and in several stages.
-> Always replace screws.
- Remove clutch.
- Remove dual-mass flywheel.
Automatic vehicles:
- Remove the engine/transmission unit.
- Remove automatic transmission.
- Removing drive plate for converter.
1. Install engine again.
2. Support engine using retaining device 9624/2.
Checking joint
Checking joint for leaks
Caution
Risk of damage due to particles of dirt.
^ Danger of material damage due to blocked oil bores/oil ducts.
-> Absolute cleanliness is essential when working on the engine.
-> Lay removed engine parts on a clean base and make sure to cover them.
-> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
View of engine/transmission flange
Joint on flywheel side
1 - Leakage points at the joint.
2 - Coated sealing screws for joint.
3 - Coated sealing screws at the intermediate shaft housing.
Warning
Caustic fluid
^ Danger of chemical burns
-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
1. Clean sealing area thoroughly with brake cleaner, acetone or solvent naphtha.
2. Coat sealing area with talcum powder or spray with leak-locating spray (spot check).
3. Fit dual-mass flywheel (also for automatic vehicles, to compensate mass of crankshaft).
Information
^ The vehicle must be lowered on the lifting platform to heat the engine.
^ If the vehicle is placed on its wheels or moved in the workshop, the rear axle carrier must always be refitted. Otherwise this may alter the axle adjustment values.
4. Start the engine and allow it to warm up. On reaching the operating temperature (check using PIWIS Tester 9718) rev to different rpm ranges several times (by pressing accelerator pedal).
Required warm-up time 30-40 minutes.
5. Allow engine to cool down sufficiently.
6. Remove dual-mass flywheel. Locate leaks.
7. Remove test medium residue in sealing area.
8. If leaks are found, the relevant repairs must be carried out as described in the PIWIS information system.
Subsequent work
Automatic vehicles:
- Remove engine.
- Install drive plate for torque converter.
-> Initial tightening: 25 Nm (19 ftlb.)
-> Torque angle: 120°
- Mount automatic transmission.
- Install engine/transmission unit.
Manual transmission vehicles:
- Install flywheel.
-> Initial tightening: 25 Nm (19 ftlb.)
-> Torque angle: 120°
Caution
Clutch pressure plate not loosened and tightened correctly.
^ Pressure plate can be deformed.
-> Always loosen and tighten screws crosswise and in several stages.
-> Always replace screws.
- Install clutch.
-> Tightening torque: 23 Nm (17 ftlb.)