Front Engine Plate: Service and Repair

Front sealing flange, removing and installing

Special tools, testers and auxiliary items required

^ Electric drill with plastic brush attachment
^ Silicone sealant D 176 404 A2

Removing

- Remove ribbed belt and tensioning element.
- Remove toothed belt.
- Remove lower air duct.





- Remove crankshaft sprocket. To do this counter-hold sprocket with 3099 retainer.
- When installing retainer, place 2 washers between sprocket and retainer.

Note:
On some engines there is a rib on the oil pan flange which prevents retainer 3099 from being attached as shown. In this case proceed as follows:

- Remove bolts from retainer, and screw back in from the reverse side.
- Knock the fitted pins in the square bars downward until they are flush with the top surface of the bars.
- Bolt the retainer to the crankshaft (install 2 washers between sprocket and retainer).
- Drain engine oil.
- Remove oil pan.
- Unbolt front sealing flange.
- Remove sealing flange. Release flange by tapping lightly with a rubber hammer if necessary.
- Remove sealant remaining on cylinder block with flat scraper.





- Remove sealant remaining on sealing flange (with rotating plastic brush or similar).

WARNING!
Wear eye protection

- Clean sealing surfaces; they must be free of oil and grease.

Installing

Note:
The sealing flange must be installed within 5 minutes after applying silicone sealant.





- Cut off nozzle of tube at front marking (nozzle diameter approx. 3 mm).

Sealant should applied in a bead 2 - 3 mm wide (arrows).

Note:
The bead of sealant must not be thicker than 3 mm, otherwise excess sealant can enter the oil pan and obstruct the filter screen in the oil intake line.





- Apply bead of silicone sealant onto clean sealing surfaces of sealing flange, as illustrated.
- Install sealing flange immediately, and tighten all bolts lightly.

Note:





To install sealing flange with the oil seal already installed, use guide sleeve from 2080A.

- Tighten bolts on sealing flange in diagonal sequence.
- Install oil sump.

Note:
After installing, the sealant must be allowed to dry for about 30 minutes before filling with engine oil.

- Install crankshaft sprocket.

Note:
Replace central bolt for sprocket.

- Install toothed belt (adjust valve timing).
- Install ribbed belt and tensioning element.

Tightening torques

^ Sealing flange to cylinder block: 15 Nm
^ Toothed belt sprocket to crankshaft: 90 Nm + 1/4 turn (90 degrees) further