11 21 505 Sealing crankcase lower section (N20)

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Special tools required:

IMPORTANT: Changed procedure.

It is not necessary to remove the cylinder head and the crankshaft.

Necessary preliminary tasks:

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove clutch (if fitted).
Remove left and right engine support arm. See LEFT ENGINE SUPPORT ARM and RIGHT ENGINE SUPPORT ARM .
Remove oil sump. See OIL SUMP (RWD) or OIL SUMP (AWD) .
Remove VIBRATION DAMPER .
Remove COUNTERBALANCE SHAFT .

Release hose clamp (1) and detach coolant hose.

Tightening torque: 11 51 3AZ .

Unfasten plug connection (2) and disconnect.

Release screws (3) and remove coolant pump.

Tightening torque: 11 51 2AZ .

Fig 1: Identifying Coolant Hose, Clamp, Plug Connection And Screws

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Release screw (1).

Tightening torque 11 42 6AZ .

Remove oil return line (2).

Installation note:

Replace O-ring.

Remove vent line (3).

Fig 2: Identifying Oil Return Line, Vent Line And Screw

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NOTE: The dowel hole for the TDC setting is on the exhaust side below the exhaust manifold.

Rotate engine at central bolt and secure flywheel in position with special tool 11 0 300 .

Fig 3: Securing Flywheel In Position Using Special Tool (11 0 300)

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Secure flywheel with special tool (1) 11 9 260 .

NOTE: Ensure that special tool 11 9 260 is fully engaged in the flywheel gearing.

Fig 4: Securing Flywheel Using Special Tool (11 9 260)

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Automatic transmission:

Release flywheel bolts (1).

Release special tool (2).

Remove flywheel (3).

Fig 5: Identifying Flywheel, Bolts, And Special Tool

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Manual gearbox:

IMPORTANT: Position crankshaft at TDC.

Remove dual-mass flywheel.

Secure flywheel with special tool 11 9 260 .

Release flywheel bolts with special tool 11 4 180 /

Fig 6: Identifying Flywheel, Bolts, And Special Tools

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IMPORTANT: Magnet wheel (1) is magnetic.
Keep magnet wheel (1) in a plastic bag away from metallic debris.

Remove magnet wheel (1) from crankshaft.

Installation note:

Check the fitting sleeve for damage.

Note the installation position of the magnet wheel.

Fig 7: Identifying Magnet Wheel On Crankshaft

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Release screw on pulse sensor (1).

Slide PULSE SENSOR (2) upwards.

Fig 8: Identifying Pulse Sensor And Screw

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Release all crankcase bolts (1) along line (2).

Fig 9: Identifying Crankcase Bolts

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Release crankcase bolts M10 in sequence 10 to 1.

Fig 10: Crankcase Lower Section Bolts Tightening/Loosening Sequence (N20)

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Release crankcase lower section (1) from crankcase upper section (2) with suitable tool (3)

Remove crankcase lower section (1) upwards.

IMPORTANT: Do not rotate crankshaft without crankcase lower section (1) (risk of damage) .

Fig 11: Releasing Crankcase Lower Section From Crankcase Upper Section

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IMPORTANT: Timing chain is preloaded.
Do not raise crankshaft.

Carefully remove radial shaft seal (1).

Catch escaping engine oil with a cloth (2).

Fig 12: Removing Radial Shaft Seal

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Carefully remove radial shaft seal (1) towards front.

Catch escaping engine oil with a cloth (2).

Fig 13: Removing Radial Shaft Seal

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IMPORTANT: Protect crankcase against sealant residues with a cloth (1).
Remove sealing compound residues (1) with special tool 11 4 470 .

Fig 14: Protecting Crankcase Against Sealant Residues Using Cloth

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Fig 15: Identifying Sealing Bead

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Installation note:

Check durability of sealing compound, do not use sealing compound that has expired.

Maximum processing time of the SEALING COMPOUND 2.2 10 minutes.

Apply sealing compound in the stated areas with a width of 2.0 to 2.6 mm.

Fit crankcase lower section (watch fitting bushes).

Fig 16: Removing Crankcase Lower Section

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Screw in all M10 crankcase screws in the sequence 1 to 10 and tighten with JOINING TORQUE .

Fig 17: Crankcase Lower Section Bolts Tightening/Loosening Sequence (N20)

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Identify all M10 crankcase bolts with a colored marking (1) for checking.

Fig 18: Identifying Marking Across Heads Of Crankcase Bolts

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Retighten all screws using special tool 00 9 120 , observing the specified sequence.

Tightening torque 11 11 1AZ .

Installation note:

After tightening all screws, the colored mark must be aligned in the same way.

Fig 19: Re-Tightening All Screws Using Special Tool (00 9 120)

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Fig 20: Identifying Crankcase Bolts

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Insert all crankcase screws (1) and tighten from the inside to the outside.

Tightening torque: 11 11 2AZ .

IMPORTANT: The following text describes the installation and sealing between the engine block and crankshaft seal at the front.
The engine block will not be leak proof at the outside of the crankshaft seal if you fail to comply with the individual work steps and the work sequence.

Connect supporting sleeve (1) to special tool 2 212 822 .

Position radial shaft seal (2) carefully in direction of arrow on special tool 2 212 822 .

Fig 21: Connecting Supporting Sleeve To Special Tool 2 212 822 Positioning Radial Shaft Seal