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 1/4 turn clockwise and then back counter-clockwise 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 ) 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 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 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 degree.
- 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.