Front Engine Plate: Service and Repair
Front Sealing Flange
Special tools, testers and auxiliary items required
• Crankshaft holder (3242)
• Thrust piece (T40007)
• Hand drill with plastic brush attachment
• Protective eyewear
• Silicone sealant
Removing
- Remove the front bumper.
- Remove the lock carrier.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the ribbed belt tensioner bolt - arrow - and tensioner.
- Remove the cover for the lower idler pulley.
- Remove the lower idler pulley bolt - arrow - and pulley.
- Remove the upper left and right toothed belt guards.
CAUTION!
Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).
- Rotate the crankshaft in the direction of engine rotation using the toothed belt gear center bolt to the cylinder 5 Top Dead Center (TDC) mark.
• Notch - B - aligns with mark - A -.
• Turning over the engine is performed using the center bolt of the crankshaft.
- Check the position of the camshafts:
• The large holes - arrows - on the securing plates for the camshaft gears must align on the inside.
- In case they do not align, turn one more rotation.
- Remove the coolant pipe bolt - arrow - from the oil pan.
- Remove the coolant pipe bolt - arrow - from the engine block.
- Remove the locking bolt - arrow - for the TDC marking from the upper oil pan.
• In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).
CAUTION!
Do not rotate the crankshaft while touching the TDC mark with your finger - danger of injury.
- Install the (3242) in the hole for the locking bolt.
- Remove the vibration damper bolts - 1 - from the crankshaft.
- Remove the center toothed belt guard.
- Remove the torque bracket bolts - arrows - and torque bracket.
- Remove the torque support valve (N382) bracket bolts - arrows - and bracket.
- Remove the toothed belt. Refer to => [ Toothed Belt ] Toothed Belt.
- Remove the crankshaft toothed belt gear - 1 - center bolt - 2 -.
- Remove the toothed belt gear.
- Remove the eccentric roller bolt - 3 - and roller, tensioning lever bolt - 2 - and lever, and the tensioning element bolts - 1 - and element.
- Remove the spray jet valve - 2 -.
- Remove the bolts - 1 -.
- Remove the lower oil pan. Refer to => [ Lower Oil Pan ] Lower Oil Pan.
- Remove the bolts - 1 and 2 -.
- Remove the front sealing flange.
- Drive out the seal from the removed flange.
- Mark the front surface of the thrust washer - arrow - using a waterproof felt tip pen.
- Remove the thrust washer from the crankshaft.
• Illustration is shown with the sealing flange installed.
Installing
• Replace the gaskets, seals and O-rings.
- Place a cloth over the open part of the oil pan.
- Carefully remove the remaining sealant from the upper oil pan.
- Remove the remaining sealant on the sealing flange using a rotating plastic brush.
CAUTION!
Wear safety glasses.
- Clean the sealing surfaces, they must be free of oil and grease.
- Cut the tube nozzle at the front marking (nozzle diameter approximately 1 mm).
- Place the new gasket - 1 - onto the cylinder block.
- Apply 2 thin silicone beads - arrows - between the cylinder block and upper oil pan.
- Thinly coat the lower sealing surface of the sealing flange with silicone sealant (hatched area).
• The sealing flange must be installed within 5 minutes after application of the silicon sealant.
- Carefully slide the sealing flange onto the reamed bolt in the cylinder block.
- Tighten the bolts - 1 - and the spray jet valve - 2 -.
- Tighten the bolts - 1 and 2 -.
- Install the lower oil pan. Refer to => [ Lower Oil Pan ] Lower Oil Pan.
- Do not oil the sealing lip and outer edge of the seal before pressing it in.
- Press in the seal using the (T40007) and the center bolt. Rotate the thrust washer and install it on the crankshaft.
• The thrust washer is rotated so that the new sealing ring runs on new sealing path.
• Marked front surface of thrust washer must now point toward engine.
- Install the crankshaft toothed belt gear - 1 - with a new center bolt - 2 -.
• There must be no oil on the contact surface between the toothed belt gear and crankshaft.
• Do not oil the bolt for crankshaft toothed belt gear.
• Note the washer below the tensioning lever.
Further installation is performed in reverse order of removal, noting the following:
• Secure all hose connections using hose clamps appropriate for the model type.
- Install the toothed belt (adjust timing). Refer to => [ Toothed Belt ] Toothed Belt.
- Install the lock carrier with attachments.
- Install the torque support. Refer to => [ Torque Bracket and Support Valve Assembly Overview ] Torque Bracket and Support Valve Assembly Overview.
Tightening Specifications
• 1) Replace bolt
• 2) 90° corresponds to a quarter turn.
• 3) 180° corresponds to one half rotation.