Camshaft Oil Seal: Service and Repair

Special Tools:
- Counterhold tool No. 999 5199, or equivalent
- Drift tool No. 999 5449, or equivalent
- Drift tool No. 999 5450, or equivalent
- Locking tool No. 999 5451, or equivalent
- Locking tool No. 999 5452, or equivalent
- Extractor tool No. 999 5919, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to Service and Repair. Tools For Engine Service and Repair

Procedures

NOTE:
- For front seal replacement, refer to steps 1-10
- For rear seal replacement, refer to steps 11-13

Front Seal





1. Remove:
- spark plug cover
- two fuel pipe clips
- lift expansion tank, place on engine
- front timing cover
- right front wheel
Undo right wing liner to expose vibration damper.





2. Turn engine crankshaft clockwise:
- Align cam/crankshaft timing marks until all timing marks are aligned.
- Remove upper timing cover.





3. Remove timing belt:
- Mark camshaft pulleys (intake and exhaust).
- Remove:
tensioner
timing belt, fold to one side
camshaft pulleys, use counterhold tool No. 999 5199, or equivalent





4. Remove and replace camshaft seal(s)
- Remove camshaft seal(s)
- Grease and install new seal with drift tool No. 999 5449, or equivalent, use copper mallet.
The later model of tool No. drift 999 5449, or equivalent is made of plastic.

NOTE: The later version of the sealing rings must be removed with extractor tool no. 999 5919, or equivalent, because of reduced space between the camshaft and the sealing ring support.





5. Remove:
- air cleaner (ACL), with hoses
- distributor cover, rotor
- camshaft position (CMP) sensor housing and damper
- engine coolant fan
- starter motor

NOTE: Solenoid valve connectors and ACL hoses.





6. Install locking tool No. 999 5451 and tool No. 999 5452, or equivalent:
- Remove plug and install locking tool No. 999 5451, or equivalent on crankshaft; turn crankshaft counter clockwise until it stops against the drift.
- Install camshaft locking tool No. 999 5452, or equivalent at the rear of the camshafts and extensions.





7. Install:
- camshaft pulley, with two bolts until they just touch the pulleys
- tensioners
- timing belt

NOTE: Check that the camshaft bolt holes are centered, as illustrated.





8. Tension timing belt:
- Remove locking pin from tensioner.
- Push the belt hard or strike it twice with a plastic mallet in the directions indicated by arrows 1 and 2.
- Tighten camshaft pulley screws, tighten to 20 Nm (15 ft lb)
- Remove camshaft locking tool No. 999 5452, or equivalent from the rear of the camshafts.
- Remove crankshaft locking tool No. 999 5451, or equivalent (install plug).
- Install upper timing cover.
- Turn crankshaft two revolutions and check that the timing marks are aligned.





9. Install:
- front timing cover
- expansion tank
- two fuel pipe clips.





10. Install:
- CMP sensor housing and damper
- rotor and distributor cover
- ACL with hoses
- spark plug cover
- starter motor
- engine coolant fan
- wing liner and wheel

Carry out function test:
- Test run engine.

Rear Seal





11. Remove:
- ACL with hoses and connectors
- distributor cover, rotor
- CMP sensor housing and damper

NOTE: Solenoid valve connectors and hoses on the ACL.





12. Remove and replace seal:
- Carefully pry out seal with a screwdriver.
- Clean seal seat and check for shaft end grooving.
- Grease new seal.
- Install the new seal by pressing it in with drift tool No. 999 5450, or equivalent.

NOTE:
- Seal is normally installed flush with the inner chamfer edge.
- If there are grooves on the shaft end the seal can be pressed in a further 2 mm by reversing the sleeve.





13. Install:
- CMP sensor housing and damper
- rotor and distributor cover
- ACL with hoses and connectors

Carry out function test:
- Test run engine.