Replacing front crankshaft seal

WARNING: High-voltage system.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!

All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
For additional information see: SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
For additional information see: NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

WARNING: Working on 12 V electrical system.
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

NOTE: RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS).
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults.

Detach battery terminal from battery pole by carefully shifting. Do not pry off using a tool.

Preliminary work

Refer to REMOVING FLAP IN LUGGAGE COMPARTMENT TRIM PANEL ON RIGHT .
Refer to DE-ENERGIZING THE HIGH-VOLTAGE SYSTEM
Refer to CHECKING THAT NO VOLTAGE IS APPLIED
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE (STARTER UNIT BATTERY) .
Refer to REMOVING BATTERY COVER IN TRUNK .
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING RESONATOR
Refer to REMOVING CLEAN AIR PIPE
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
Refer to REMOVING THE DRIVE BELT FOR COOLANT PUMP .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING STARTER MOTOR .
Refer to REMOVING THE VIBRATION DAMPER .

Removing the front crankshaft seal

Drive in the crankshaft seal (1) in the marked area with a punch to approx. 1 cm deep.

Courtesy of BMW OF NORTH AMERICA, INC.
Lever out the crankshaft sealing ring (1) with the special tool 2 298 505 .
Make sure that the sealing surface on the crankcase is not scratched.

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Installing the front crankshaft seal
Prepare special tool 0 496 130 (11 8 803) .

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Clean the special tool 0 496 128 (11 8 801) from the set of special tools 0 496 127 (11 8 800) and coat it with motor oil.
Secure special tool 0 496 128 (11 8 801) to the crankshaft using special tool 0 496 129 (11 8 802) from the set of special tools 0 496 127 (11 8 800) .

Courtesy of BMW OF NORTH AMERICA, INC.
NOTE:
RISK OF DAMAGE
Radial shaft seal damage.
Taping the sealing lip (inner) and applying oil to the radial shaft seal will lead to its destruction.
- Do not tap the sealing lip (inner) of the radial shaft seal.
- Do not apply oil to the radial shaft seal.
- Install the radial shaft seal dry.
Courtesy of BMW OF NORTH AMERICA, INC.
Carefully slide the crankshaft sealing ring (1) straight in a rotational movement onto the special tool 0 496 128 (11 8 801) from the set of special tools 0 496 127 (11 8 800) until the crankshaft sealing ring (1) is positioned flush against the crankcase.
Mount the special tool 0 496 130 (11 8 803) on special tool 0 496 128 (11 8 801) of the set of special tools 0 496 127 (11 8 800) in arrow direction.

Courtesy of BMW OF NORTH AMERICA, INC.

Screw in the special tool (sleeve) 0 496 130 (11 8 803) using the special tool 0 496 131 (11 8 804) from the set of special tools 0 496 127 (11 8 800) and a suitable tool until the sleeve is positioned flush against the crankcase (1).

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Release the special tool 0 496 131 (11 8 804) and remove.

Courtesy of BMW OF NORTH AMERICA, INC.
Feed out and remove the special tool 0 496 130 (11 8 803) on the special tool 0 496 128 (11 8 801) of the set of special tools 0 496 127 (11 8 800) in arrow direction.

Courtesy of BMW OF NORTH AMERICA, INC.

Release the special tool 0 496 129 (11 8 802) .
Feed out and remove the special tool 0 496 128 (11 8 801) 0 496 129 (11 8 802) on the crankshaft.

Courtesy of BMW OF NORTH AMERICA, INC.
Check the crankshaft sealing ring (1) for correct installation on the crankcase (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Follow-up work

Refer to INSTALLING THE VIBRATION DAMPER .
Refer to INSTALLING STARTER MOTOR .
Refer to INSTALLING THE DRIVE BELT FOR THE COOLANT PUMP .
Refer to INSTALL THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING CLEAN AIR PIPE .
Refer to INSTALLING RESONATOR .
Refer to INSTALLING ACOUSTIC COVER .
Refer to CONNECTING NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY .
Refer to INSTALLING BATTERY COVER IN TRUNK .
Refer to CONNECTING THE NEGATIVE BATTERY CABLE (12 V BATTERY) .
Refer to ACTIVATING HIGH-VOLTAGE SYSTEM .
Refer to INSTALLING FLAP IN RIGHT LUGGAGE COMPARTMENT TRIM PANEL .
Refer to CHECKING ENGINE OIL LEVEL .
Refer to INSTALLING UNDERBODY PROTECTION AT REAR .
Refer to INSTALLING THE CENTER UNDERBODY PROTECTION .
Refer to INSTALLING THE FRONT UNDERBODY PROTECTION .