Front Crankshaft Seal: Service and Repair

REPLACING FRONT SEALS FOR CAMSHAFT, INTERMEDIATE SHAFT AND CRANKSHAFT

Special Tools Required: 5284, 5025, 5034.




Check that flame guard is not blocked.
A blocked flame guard prevents crankcase ventilation from operating properly. Crankcase pressure will be too high.

NOTE: Flame guard should not be installed on turbo engines.

Symptoms of a blocked flame guard are:
- oil dipstick pops up of pipe.
- oil leaks from oil seals in cylinder block. The oil seals need not always be replaced if they leak due to a blocked flame guard. Clean flame guard and engine and recheck seals for leakage
- engine knocks.


REMOVAL PROCEDURE:

Disconnect battery ground cable.




Remove:
- cooling fan
- clamp for preheating hose below fan shroud (optional)
- fan shroud

Remove drive belts and coolant pump pulley
- loosen adjustments
- remove AC compressor and alternator belts
- remove pulley




Remove upper timing belt cover
- 1 10 mm socket M 6 bolt
- 2 12 mm socket M 8 bolt
- 3 Phillips screwdriver sheet metal screws




Set camshaft and crankshaft according to markings
Use center bolt to turn crankshaft. Set camshaft so that marking on pulley is opposite marking on inner timing belt cover and crankshaft marking opposite 0 on cover.

Engines with side-mounted distributor: remove cap and check that rotor points opposite marking.




Remove Vibration Damper:
- Remove nut and washer from timing belt tensioner.
- Install tool 5284. Use nut to retain it.
- Remove bolt for vibration damper. Remove tool 5284.
- Check/adjust 0 marking.
- Remove vibration damper.




Remove lower timing belt cover
- 1 10 mm socket M 6 bolt
- 2 12 mm socket M 8 bolt




Remove Timing Belt
- Pull on timing belt to depress belt tensioner spring and lock it with a 3 mm drill.
- Remove timing belt.

CAUTION: Do not turn crankshaft or camshaft. Pistons may strike valves.

Check which seal is leaking


REPLACING CAMSHAFT AND/OR INTERMEDIATE SHAFT SEAL




Remove pulley at seal to be replaced
Use tool 5034.




Remove timing belt tensioner
Pull straight out.

Remove inner timing belt cover




Remove seal to be replaced
Carefully pry loose seal with a screwdriver. The contact face must not become damaged.

Clean and check contact faces
for scoring and other damages.





Install new seal
Grease seal and seat

Use sleeve 5025 and press in seal

Note: Make sure seal is not distorted or damaged during fitting.

Install inner timing belt cover




Install timing belt tensioner

Install pulleys as applicable

Position guide plates of camshaft pulley so that they incline outwards from pulley.

Position intermediate shaft pulley with marking (a cavity) outwards.

Hold pulley using tool 5034.

Torque to 50 Nm (36 ft lbs).


REPLACING CRANKSHAFT SEAL




Remove oil seal
Carefully pry loose seal with a screwdriver. Contact face must not become damaged.

Clean and check contact faces
for scoring and other damages.




Install new seal
Grease seal and seat

Press in seal. Use sleeve 5283.

Note: Make sure seal is not distorted or damaged during fitting.





Check basic setting

Install timing belt

IMPORTANT! Do not turn crankshaft or camshaft. Pistons may strike valves.

- Position pulley according to marking.
- Install timing belt on crankshaft and camshaft. Two lines on timing belt should be opposite crankshaft marking.
- Stretch timing belt and install it on camshaft and belt tensioner.
- Make sure timing belt is correctly positioned and that pulley markings are opposite markings on engine.




Install lower timing belt cover and vibration damper
Use counterhold 5284.
Torque crankshaft center bolt.
Stage 1 60 Nm (45 ft lbs).
Stage 2 Angle-tighten 60°.




Tension Timing Belt:
- Install nut and washer for belt tensioner finger tight.
- Pull timing belt to depress belt tensioner and remove locking drill.
- Tensioner spring will now tension timing belt.
- Tighten tensioner nut.




Install:
- upper timing belt cover.
- pulley.
- drive belts loosely.
- fan shroud.
- clamp for preheating hose.
- cooling fan.

Tension drive belts
With correct tension, it should be possible to depress belt 510 mm (0.2-0.4 in) by thumb pressure.
Connect battery ground cable

Run engine warm and check/adjust:
- ignition timing
- CO
- idle speed
- for leakages

Switch off engine.




Readjust timing belt
- Rotate engine until at top dead center.
- Remove rubber plug on timing belt cover.
- Loosen belt tensioner nut approx 1 turn.
- Tensioner spring will not tension timing belt.
- Tighten tensioner nut.
- Install rubber plug.

After driving approx. 1000 km - 600 miles: Tension timing belt.