Front Engine Plate: Service and Repair

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items required

• Spanner Wrench (3212)

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant, refer to the Parts Catalog

Removing

- Remove the coolant thermostat and connection. Refer to => [ Connecting Piece with Coolant Thermostat ] Service and Repair.

- Remove the vibration damper with the ribbed belt pulley. Refer to => [ Vibration Damper with Ribbed Belt Pulley, ] Service and Repair.

- Remove the bolt - 1 -.






• Ignore - arrow -.

- Tilt the toothed belt guard forward - arrows - and disengage the pins on the underside of the guard.






• The toothed belt guard is shown with the intake manifold upper section removed.

- Remove the bolts - arrows - for the coolant pump ribbed belt pulley using a (3212) to counterhold.






- Remove the bolt - 1 - and nut - 2 -.






- Remove the right coolant pipe from the cylinder block and move it to the side.

- Pry the cover off the ribbed belt idler roller.






- Remove the bolt - arrow - and remove the idler roller from the pulley side sealing flange.

- Remove the bolts.






- First remove the right pulley side sealing flange - arrows 1 - and then the left one - arrows 2 -.

- Remove the crankshaft seal on the removed sealing flange.

Installing

• Tightening specifications, refer to => [ Ribbed Belt Drive Overview ] Ribbed Belt Drive Overview, => [ Seal and Sealing Flange, Pulley Side Overview ] Seal and Sealing Flange, Pulley Side Overview.

• Replace the crankshaft seals, O-rings and sealing rings.

- Remove any old sealant from the grooves on the sealing flange as well as from the sealing surfaces.

Risk of contaminating lubricating system.

• Cover open parts of the engine.

Risk of eye injury.

• Wear protective eyewear.

- Remove sealant residue on the sealing flange and the cylinder block and the upper section of the oil pan, for example using a rotating plastic brush.






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

• Note the expiration date of the sealing compound.

- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).






- Install the seals - 2 - and - 4 - and O-rings - 1 - and - 3 -.






The lubrication system could be plugged with excess sealant.

• Do not apply sealant bead thicker than specified.

- Apply sealant bead - arrow - to clean sealing flange pulley side sealing surface as shown in illustration.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

• The ribbed belt side sealing flange must be installed within 5 minutes of applying the sealant.

- Tighten pulley side sealing flange bolts. Refer to => [ Ribbed Belt Pulley Side Sealing Flange - Tightening Specifications and Sequence ] Seal and Sealing Flange, Pulley Side Overview.






The rest of the installation is performed in reverse order of removal, noting the following:

- Install the pulley-side crankshaft shaft seal. Refer to => [ Crankshaft Shaft Seal, Belt Pulley Side, Replacing ] Crankshaft Shaft Seal, Belt Pulley Side, Replacing.

- Install right coolant pipe. Refer to => [ Coolant Pipes Overview ] Coolant Pipes Overview.

- Install the coolant pump ribbed belt pulley. Refer to => [ Coolant Pump and Coolant Thermostat Overview ] Service and Repair.

- Install the vibration damper with ribbed belt pulley. Refer to => [ Vibration Damper with Ribbed Belt Pulley, ] Service and Repair.

- Install the coolant thermostat and connection. Refer to => [ Connecting Piece with Coolant Thermostat ] Service and Repair.