Front Engine Plate: Service and Repair

Front Sealing Flange

Special tools, testers and auxiliary items required

• Spanner Wrench (3212)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Silicone Sealant (D 176 404 A2)

Removing

- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Remove the vibration damper.

- Remove the coolant pump pulley. When loosening the bolts - arrows - use the spanner wrench (3212) to counter hold the pulley.






- Pry the cap off the ribbed belt idler pulley.






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

- Remove the noise insulation retainers - arrows - and insulation from the sealing flange.






- Loosen the nut for the coolant pipe.

- Pry the tab upward out of the coolant pipe.

- Remove the sealing flange bolts.






- Remove the front sealing flange from the right side first - arrow 1 - and then from the left side - arrow 2 -.

- Drive out the seal from the removed flange.

Installing

• Replace the gaskets and O-rings.

- Remove the sealant from the groves on the sealing flange and from the sealing surfaces.

Wear protective eyewear.

- Remove any sealant residue from the sealing flange and the cylinder block or upper oil pan with a rotating plastic brush.






- Clean the sealing surfaces so they are completely free of any oil or grease.

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






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






- Apply a bead of sealant - arrow - to the clean sealing surfaces on the sealing flange as illustrated.

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

• The sealant bead must not be thicker than specified, otherwise the excess sealant could get into oil pan and clog the oil pump strainer.

• The front sealing flange must be installed within 5 minutes of being applied with sealant.

- Tighten the sealing flange bolts in a diagonal sequence in stages. Tightening specification: 9 Nm.






- Install the new seal. Refer to => [ Crankshaft Seal, Belt Pulley Side ] Crankshaft Seal, Belt Pulley Side.

Further installation is performed in the reverse order of removal.