Front crankshaft seal, to change
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Front crankshaft seal, to change
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1.
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Drape wing protectors over the wings and raise the car.
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2.
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Remove the lower spoiler sections.
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3.
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Insert two
83 95 238 Wedges
, between the oil sump and subframe and between the gearbox and subframe.
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5.
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Remove the mass air flow sensor with hose.
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6.
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Detach the power steering hose from the holder.
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7.
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Remove the right-hand engine attachment with bracket and engine mount.
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8.
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Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
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9.
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Release the multigroove belt from tension.
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10.
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Remove the coolant pump pulley and power steering pump pulley.
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11.
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Remove the belt tensioner and generator air intake.
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12.
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Remove the timing cover.
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13.
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Remove the crankshaft pulley.
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14.
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Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use
Installation tool for camshaft sprockets and camshaft drive belt
KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.
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15.
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Loosen the tension pulley and the upper adjusting roller. Use Wrench 83 94 983 as a holding tool on the adjusting roller.
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16.
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When refitting a timing belt:
Mark the belt's direction of rotation. In order to facilitate fitting, the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Keep the locking tools KM-800-1 and KM-800-2 in place. Remove the lower adjusting roller. Make sure that the washer behind the roller comes off as well. Remove the timing belt.
When fitting a new timing belt
: Remove the timing belt.
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17.
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Rotate the crankshaft to 60° BTDC
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19.
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Fit the
Counterstay
, part no. 83 95 063 and remove the crankshaft's timing belt sprocket and spacer ring.
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20.
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Use a screwdriver to prise out the old seal, taking care not to damage the sealing surface.
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1.
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Fit the inner part of
Assembly tool for front crankshaft seal
part no. 83 94 942, to the crankshaft with the taper outward. Lubricate the seal and place it on the shaft. Tap in the seal with the outer part of the tool.
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2.
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Fit the spacer ring. Place part no. (10) 93 21 795 on the back of the crankshaft timing belt sprocket and fit it in place. Use
Counterstay
, part no. 83 95 063. Remove the counterstay.
Tightening torque:
250 Nm (184.5 lbf ft) + 45°
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4.
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Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets.
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5.
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Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
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6.
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Refitting a marked timing belt:
Fit the timing belt in accordance with the marking on the belt and the marked direction of rotation. Use
Adjustment tools for cam sprocket and timing belt
KM-800-30 in order to hold the belt in place. Fit the lower guide roller. Make sure that the washer is fitted correctly. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30.
Fitting a new unmarked timing belt:
Fit the new timing belt in accordance with the belt's direction of rotation. Use
Adjustment tools for cam sprocket and timing belt
KM-800-30 in order to hold the belt in place. Fit the lower tension pulley. Make sure that the washer is fitted correctly. Remove the tool KM-800-30.
Fit locking tool KM-800-10, position a piece of timing belt and fit
Belt tension gauge
part no. 83 93 985 to measure the belt tension.
Tighten the centre bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300 Nm is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use tool 83 94 983 as a counterstay. Check the belt tension again and adjust as necessary.
Tightening torque: 40 Nm (30 lbf ft)
Remove the belt tension gauge and piece of timing belt.
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Important
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Adjustment of belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.
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7.
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Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tension pulley with a 5 mm Allen key until the two lines on the tension pulley correspond with each other. Tighten.
Tightening torque: 20 Nm (15 lbf ft)
Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprocket are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay.
Tightening torque: 40 Nm (30 lbf ft)
Remove KM-800-20 and the other locking tools
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8.
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Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
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Important
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Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
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9.
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Fit the crankshaft pulley.
Tightening torque: 20 Nm (15 lbf ft)
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10.
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Fit the timing cover.
Tightening torque: 8 Nm (6 lbf ft)
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11.
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Fit the belt tensioner and the generator air intake.
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12.
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Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
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13.
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Fit the multigroove belt.
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14.
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Tighten the retaining bolts on the pulleys.
Tightening torque:
Belt pulley/coolant pump: 8 Nm (6 lbf ft)
Belt pulley/power steering pump: 20 Nm (15 lbf ft)
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15.
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Fit the right-hand engine attachment with bracket and engine mount.
Tightening torque:
To body 63 Nm (46.5 lbf ft)
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16.
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Fit the power steering hose in the holder
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17.
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Fit the mass air flow sensor with hose.
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19.
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Lower the engine by carefully removing the wedges.
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20.
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Fit the lower spoiler sections.
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21.
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Lower the car and remove the wing protectors.
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