Procedures

Replacing The Oil Pump/Front Crankshaft Seal

Special Tools: 998 6187, 999 5433, 999 5455, 999 5919, 999 5747, 951 2050.

NOTE:
- As the illustrations in the information are used for different model years and/or models, certain variations may occur. However, the essential information in the illustrations is always correct.
- If the oil pressure is low or if there is possibly a fault with the oil pump, measure the oil pressure.

Remove Engine Components

Remove:

CAUTION: Remove the ignition key from the ignition switch before beginning work.







- the upper camshaft belt cover.
- the servo reservoir and expansion tank.

Lift up and place on top of the engine.

NOTE: Ensure that no power steering fluid is spilled. It is extremely flammable.

- the auxiliaries belt.
- the front camshaft belt cover.

Position The Engine According To The Marking
Raise The Car







- Remove the right front wheel.
- Install the upper timing belt cover.
- Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
- Turn a further one-quarter turn clockwise and then back counterclockwise until the markings correspond.
- Remove the upper camshaft cover.

Remove The Timing Belt







- Slacken off the belt tensioner center screw slightly.
- Hold the center screw still and turn the tensioner eccentric clockwise with a 6 mm (15/64 inch.) Allen key to "10 O'clock".
- Remove the timing belt.

Remove The Vibration Damper







- Install counterhold 999 5433.
- Counterhold and remove the crankshaft center nut.
- Work the vibration damper loose and remove by hand.
- Remove the timing belt.

Remove The Crankshaft Timing Gear Pulley







- Use a universal puller 998 6187 and two of the vibration damper screws.
- Tighten both the screws by hand to stop in the pulley.
- Install puller so that the claws are on the screws, not in the camshaft pulley.

NOTE: Ensure that the tool claws do not damage the pulley teeth.

When Replacing The Front Crankshaft Seal







- Remove the old seal using a groove-cut chisel or: 999 5919.
- Clean the mating surface.
- Grease and install a new seal. Use tool 999 5455.
- Press in the seal using a drift and the crankshaft center nut as shown in the above figure.

NOTE: Check thoroughly that the crankshaft does not rotate when pressing in the crankshaft seal.

Remove The Oil Pump







- Remove the four oil pump screws.
- Remove the oil pump.
- Use a groove-cut chisel and carefully break at the stop lugs.

- Clean the gasket face and the mating surfaces.

Install The Oil Pump







- Install a new oil pump
- Install a new gasket and new O-ring around the pump housing.
- Screw in sliding sleeve 999 5747.
- Carefully slide in the oil pump over the crankshaft end.

NOTE: Take great care so that the sealing ring in the oil pump is not damaged during installation.

- Carefully tap in the oil pump with a rubber mallet.
- Tighten the screws crosswise to 10 Nm (7.4 lb.ft).
- Install the crankshaft timing gear pulley. Carefully tap alternately around the wheel until end position is reached.

NOTE: The timing gear pulley can only be in one position on the crankshaft end splines.

Install The Vibration Damper







- Install the new camshaft belt over the crankshaft pulley wheel.
- Install the vibration damper.
- Tighten the center nut to 180 Nm (133 lb.ft).
- Use counterhold 999 5433.

- Remove the counterhold and install new screws.
- Tighten the screws to 25 Nm (18 lb.ft).
- Angle-tighten 30 degrees.
- Use bevel protractor 951 2050.

Install The Camshaft Belt







- Install the upper camshaft belt cover.
- Check that the markings on the crankshaft and camshaft timing gear pulley correspond.

Install The Belt In The Following Order:
1. crankshaft
2. idler pulley
3. intake camshaft
4. exhaust camshaft
5. water pump
6. belt tensioner

Tighten The Timing Belt







This adjustment must always be made on a cold engine.

The correct temperature is approximately 20 degree C / 68 degree F.

At higher temperatures, for example with engine at operating temperature, the indicator is further to right.

The position of the indicator when aligning the camshaft belt tensioner at different temperatures is shown in the figure.







Turn the crankshaft clockwise carefully until the camshaft belt is tensioned.

The belt must be tight between the intake cam, the idler pulley and the crankshaft.

Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.

Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.

Secure the eccentric and tighten the center screw to 20 Nm (15 lb.ft).

Check that the indicator is in the correct position.

A new alignment must be carried out if the indicator is not in the correct position.

Check







- Press the belt to check that the indicator on the tensioner moves easily.
- Install the upper timing belt cover.
- Turn the crankshaft 2 turns and check that the markings on the crankshaft and camshaft pulley correspond.
- Check that the indicator on the belt tensioner is within the marked position.

Install the nuts for the cover in the fender liner.
Install the wheel.

Finishing

Install:







- the front camshaft belt cover. Tighten to 12 Nm (8.8 lb.ft).
- the upper camshaft belt cover.
- the auxiliaries belt.
- the expansion tank and servo reservoir.

NOTE: Ensure that the hoses are correctly positioned.

Carry Out A Function Test
- Check the oil level and top up if required.
- Start the engine.

NOTE: Check that there is no leakage.

- Stop the engine and give the oil time to run down into the oil trough.
- Then check the oil level.
- Top up if necessary.

NOTE: Check again that there is no leakage.

- Wipe the engine compartment clean.
- Ensure that the steering wheel and gear selector lever are clean.