Front Engine Plate: Service and Repair

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items required

• Trim Removal Wedge (3409)

• Oil Seal Guide Sleeve (T03004)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 174 003 A2)

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

- Remove the Air Conditioning (A/C) compressor ribbed belt. Refer to => [ Ribbed Belts ] Ribbed Belts.

- Lock the crankshaft. Refer to => [ Crankshaft, Locking ] Procedures.

- Remove the vibration damper.

- Remove the A/C compressor ribbed belt tensioner - 1 -. Refer to => [ Ribbed Belt Tensioner, A/C Compressor Belt ] Ribbed Belt Tensioner, A/C Compressor Belt.






- Remove the sealing flange bolts - 2 -.

- Begin at the alignment sleeves - arrows -, pry off the sealing flange - 1 - using a suitable screwdriver - A -.






- Use the trim removal wedge (3409) to support the screwdriver in order to prevent damage to the sealing flange sealing surface of the cylinder block.

The sealing flange is damaged while removing.

- Pry off the sealing flange completely.

• After removing the sealing flange, clean the trim removal wedge (3409) which is intended for the removal of interior equipment parts.

Installing

To prevent injuries from shavings, wear protective goggles and protective clothing.

- Remove any remaining sealant from the cylinder block, using for example, a rotating plastic brush.

Make sure that no sealant residue enters the engine.

- Clean the sealing surface of the cylinder block and crankshaft journals; they must be free of oil and grease.

• Do not additionally lubricate or grease the sealing lip of the sealing flange seal!

• The following work steps must be followed so that the sealing lip of the sealing flange does not roll itself up when installing.

- Widen the sealing lip of the new sealing flange seal as shown, using the oil seal guide sleeve (T03004).






The surface - A - is the outer side.

- After a short time, remove the oil seal guide sleeve (T03004) and slide it, rotated 180° into the seal.






The oil seal guide sleeve (T03004) must stand out approximately 3 mm on the inner side - B -. The surface - A - is the outer side. The surface - B - is the inner side (sealing surface).

- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 2 mm).






• The sealing flange must be installed within 5 minutes after application of the sealant.

- Apply the sealant bead - A - as shown into the groove in the sealing flange.






• Width of sealant bead: 2.5 to 3.0 mm

• Height of sealant bead above the sealing surface: approximately 1.0 mm

- Install the sealing flange using the oil seal guide sleeve (T03004) onto the crankshaft journal and press it uniformly against the cylinder block.






- Tighten the bolts - A - uniformly in a diagonal sequence.

The rest of the installation follows the reverse of the removal procedure. When doing this note the following:

• Remove the locking pin (T40069) from the cylinder block and install the plug.

Tightening Specifications