Front Crankshaft Seal: Service and Repair
Removing and installing crankshaft sealing ring - pulley side
Engine installed
Tools
Information
- Use only the special tool (assembly sleeve 9610/1) to fit the radial shaft seal.
Removing the crankshaft sealing ring
Caution
Damage to the engine by penetrating dirt. When working on the engine, absolute cleanliness is essential.
Caution
Damage to the crankshaft flange due to improper cleaning
- Never use fine abrasive cloth, polishing cloth or brushes with metal bristles.
- Observe cleaning instructions
- Leaks
1. Disconnect battery.
2. Remove air cleaner housing.
1.1 Undo M6 x 34 shouldered bolt.
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 housing.
3. 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 -direction of the arrow- and simultaneously remove the belt from the tensioning roller or deflection rollers.
4. Loosen crankshaft pulley. Place the special tool (socket wrench insert 9594) with a large torque wrench onto the hexagon-head bolt (M16 x 1.5 x 60) and counter with the special tool (holding device 9593) when loosening the bolt.
5. Remove crankshaft sealing ring. The following 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 (mounting lever 9182)
- Hexagon-head tapping screw (5.0 x 20)
- Washer
- Support, e.g. wooden block measuring 50 x 30 x 20 mm
Removal procedure:
6. Use an angle drill to drill a 3 mm hole in the face side of the sealing ring. Grease the drill bit in order to trap the drilling chips. Screw a tapping screw with washer approx. 5 mm into the hole.
7. Position a lever, e.g. special tool (mounting lever 9182), on the tapping screw, place a wooden wedge between the lever and the crankcase and lever out the sealing ring. Carefully clean the remaining dirt off the crankshaft flange.
8. If there are corroded areas on the crankshaft flange, clean it with a metal-polishing pad (e.g. Nevr-Dull(R), available in car and motor bike accessory stores). Then, carefully degrease the flange and crankcase bore using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.
Information
- Visual inspection of the crankshaft flange and crankcase bore for damage.
9. Visually inspect the crankshaft flange and crankcase bore for damage.
Installing the crankshaft sealing ring
Caution
Sharp tool edges and burrs
- Always examine tools for signs of burrs and sharp edges.
- Damage to the sealing lip
Information
- Measured from the face side of the flange, the series shaft seal is pressed in 12.5 mm deep. The new sealing ring is pressed in to a depth of 14.5 mm using the mounting device of the special tool (assembly tool 9610/1) in order to produce a new running surface for the sealing lip.
1. Small burred spots or damaged areas on the tools can be eliminated with a nail file; then whet with an oilstone, fine abrasive or polishing cloth. Remove residual dirt on the tools, e.g. using solvent naphtha or acetone.
2. Apply new engine oil on the crankcase bore and manually slide the new crankshaft sealing ring over the cone of the special tool (assembly sleeve 9610/1) and onto the flange. Remove assembly sleeve.
3. Insert the new sealing ring as far as it will go using the special tool (assembly sleeve 9610/1).
4. Remove special tool.
5. Check whether the sealing ring is properly seated and aligned. To do this, measure the distance from the contact face of the pulley on the crankshaft flange to the sealing ring (outer radius) at four points offset by 90°.
Dimension from pulley contact surface to the sealing ring: 14.5 mm
Information
- Check for foreign objects in the drive-belt grooves of the pulley; clean the grooves if necessary (e.g. with a nylon brush) or replace the pulley if damaged.
6. Fit the crankshaft pulley.
7. Tighten the hexagon-head bolt to the specified torque using the special tool (socket wrench insert 9594) while countering with the special tool (holding device 9593). Then tighten the bolt to the specified torque angle.
Fitting drive belt
Information
- Visually inspect the condition of the belt; remove foreign objects from the grooves if necessary. Observe running direction (color pen marking).
1. Fit drive belt by hand, slightly pre-tensioned, in the following sequence:
1. Coolant pump pulley -Item 1-
2. Generator pulley -Item 2-
3. Deflector roller 1 -Item 3-
4. Power-steering pump pulley -Item 4-
5. Air-conditioning compressor pulley -Item 5-
6. Pulley on crankshaft -Item 6-
7. Tensioning roller -Item 7-
Then turn the tensioning roller clockwise -direction of the arrow- and simultaneously fit the drive belt on deflection roller 2 -Item 8-.
2. Visually check whether the drive belt is correctly fitted on all drive pulleys.
3. Install air cleaner housing.
4. Connect the battery.
5. Allow the engine to warm up (operating temperature) and visually inspect it for leaks.