Procedures

Removing and installing crankshaft sealing ring

Engine installed (pulley side)




Tools

Removal

1. Remove the air cleaner assembly.





1.1. Undo collar screw M 604.





1.2. Detach oil filler neck. Undo hose clamp on throttle body and pull plug off the hot film mass air flow meter. Unclip wire on air cleaner housing and remove air cleaner assembly.





2. Remove drive belt. Mark the running direction of the belt with a colored pen. Relieve the belt tension. To do this, turn the tensioning roller (wrench size 24 mm) clockwise and simultaneously remove the belt from the drive pulleys.





3. Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool 9594 (socket wrench insert); to do this, hold with special tool 9593 (retaining device).
4. Remove crankshaft sealing ring. The tools and parts are required for removal of the crankshaft sealing ring:
- Angle drill
- Drill bit, [diameter] 3 mm
- Mounting lever, e.g. special tool 918
- Sheetmetal screw with hexagon head (5.0 x 20)
- Washer
- Support, e.g. wooden block 50 x 30 x 20 mm

Removal procedure:





- Drill sealing ring on face side (refer to drawing),
- Screw sheetmetal screw with washer approximately 5 mm into the bore.
- Position mounting lever on the sheetmetal screw; place support between the mounting lever and crankcase.





- Lever crankshaft sealing ring out of the crankcase.

Installation
1. Insert new sealing ring using special tool 9610 (insertion tool):
a. Place assembly sleeve on crankshaft journal.
b. Thoroughly lubricate the crankshaft journal, assembly sleeve and sealing lip.

Note: Do not lubricate outer diameter of sealing ring; it must be fitted dry.





c. Position sealing ring by hand and push off the assembly sleeve onto the crankshaft journal.
d. Remove assembly sleeve.
e. Position hexagon-head bolt (M16 x 1.5 x 60) and outer part of special tool and insert sealing ring as far as it will go.
2. Fit belt pulley.

Note: Check whether there are foreign objects in the drive belt grooves of the pulley.








3. Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.
Tightening sequence:
Initial tightening 50 Nm (37 ft. lbs.)
Final tightening 1 x 90° turn
4. Fit drive belt.

Note: Visually inspect the condition of the belt; remove foreign objects from the grooves if necessary. Observe running direction (color pen marking).

Installation
1. Fit drive belt by hand, slightly pre-tensioned, in the sequence:
1. Coolant pump drive pulley (1)
2. Alternator drive pulley (2)
3. Deflection roller 1 (3)
4. Power steering pump drive pulley (4)
5. Air-conditioning compressor drive pulley (5)
6. Crankshaft pulley (6)
7. Tensioning roller (7)








Then turn the tensioning roller (7) in clockwise direction and simultaneously fit the drive belt on the deflection roller 2 (8).
2. Visually check whether the belt is correctly positioned on all drive pulleys.
3. Install air cleaner assembly
4. Connect the battery.
5. Perform tightness test.