Sealing Flange, Belt Pulley Side

Special tools and workshop equipment required

Spanner Wrench 3212
Hand drill with plastic brush attachment
Protective eyewear
Sealant

Removing

-- Remove the coolant thermostat and connection. Refer to CONNECTING PIECE WITH COOLANT THERMOSTAT .

-- Remove the vibration damper with the ribbed belt pulley. Refer to VIBRATION DAMPER WITH RIBBED BELT PULLEY, .

-- Remove the bolt -1-.

Fig 1: Identifying Bolt -1- And Coolant Hose -Arrow-

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NOTE:

Ignore -arrow-.

-- Tilt the toothed belt guard forward -arrows- and disengage the pins on the underside of the guard.

Fig 2: Identifying Toothed Belt Guard

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NOTE:

The toothed belt guard is shown with the intake manifold upper section removed.

-- Remove the bolts -arrows- for the coolant pump ribbed belt pulley using a 3212 to counterhold.

Fig 3: Identifying Spanner Wrench 3212 And Bolts -Arrows-

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-- Remove the bolt -1- and nut -2-.

Fig 4: Identifying Bolt -1- And Nut -2-

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-- Remove the right coolant pipe from the cylinder block and move it to the side.

-- Pry the cover off the ribbed belt idler roller.

Fig 5: Identifying Bolt -Arrow- And Idler Pulley

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

-- Remove the bolts.

Fig 6: Identifying Removal Of Front Sealing Flange Sequence -- At Right -Arrows 1- Then At Left -Arrows 2-

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-- First remove the right pulley side sealing flange -arrows 1- and then the left one -arrows 2-.

-- Remove the crankshaft seal on the removed sealing flange.

Installing

Tightening specifications, refer to RIBBED BELT DRIVE OVERVIEW , SEAL AND SEALING FLANGE, PULLEY SIDE OVERVIEW .

NOTE:

Replace the crankshaft seals, O-rings and sealing rings.

-- Remove any old sealant from the grooves on the sealing flange as well as from the sealing surfaces.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of the engine.

WARNING:

Risk of eye injury.

Wear protective eyewear.

-- Remove sealant residue on the sealing flange and the cylinder block and the upper section of the oil pan, for example using a rotating plastic brush.

Fig 7: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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-- Clean the sealing surfaces; they must be free of oil and grease.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).

Fig 8: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1.5 mm)

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

Fig 9: Identifying Seals -2 & 4-, O-rings -1 & 3- And Sealant Bead

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than specified.

-- Apply sealant bead -arrow- to clean sealing flange pulley side sealing surface as shown in illustration.

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

NOTE:

The ribbed belt side sealing flange must be installed within 5 minutes of applying the sealant.

-- Tighten pulley side sealing flange bolts. Refer to Figure.

Fig 10: Identifying Sealing Flange -Arrow- Bolts -- Tighten Diagonally

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The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the pulley-side crankshaft shaft seal. Refer to CRANKSHAFT SHAFT SEAL, BELT PULLEY SIDE, REPLACING .

-- Install right coolant pipe. Refer to COOLANT PIPES OVERVIEW .

-- Install the coolant pump ribbed belt pulley. Refer to COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW .

-- Install the vibration damper with ribbed belt pulley. Refer to VIBRATION DAMPER WITH RIBBED BELT PULLEY, .

-- Install the coolant thermostat and connection. Refer to CONNECTING PIECE WITH COOLANT THERMOSTAT .