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 .

Preliminary work

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING THE TOP LEFT COVER IN THE ENGINE COMPARTMENT , and REMOVING THE TOP RIGHT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING UPPER CROSS CONNECTION .
Refer to REMOVING THE TENSION STRUT AT THE SHOCK TOWER ON THE LEFT AND RIGHT .
Refer to REMOVING THE REAR TOP CROSS CONNECTION .
Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
Refer to REMOVING THE STIFFENING PLATE .
Refer to REMOVING FAN COWL .
Refer to REMOVING THE INTAKE FILTER HOUSING (TENSION STRUT ON SHOCK TOWER REMOVED) .
Refer to REMOVING CLEAN AIR PIPE AND RESONATOR .
Refer to REMOVING CHARGE AIR LINE .
Refer to REMOVING THE DRIVE BELT FOR COOLANT PUMP .
Refer to REMOVING THE ACOUSTIC COVER OF THE OIL SUMP .
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.

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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) .

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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.

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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.

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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.

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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.

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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.

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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 ACOUSTIC COVER FOR THE OIL SUMP .
Refer to INSTALLING THE DRIVE BELT FOR THE COOLANT PUMP .
Refer to INSTALLING CHARGE AIR LINE .
Refer to INSTALLING THE CLEAN AIR PIPE AND THE RESONATOR .
Refer to INSTALLING THE INTAKE FILTER HOUSING (TENSION STRUT REMOVED ON SHOCK TOWER) .
Refer to INSTALLING FAN COWL .
Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
Refer to INSTALLING TENSION STRUT ON LEFT AND RIGHT SHOCK TOWER .
Refer to INSTALLING UPPER CROSS CONNECTION .
Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT AT TOP LEFT , and INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE TOP RIGHT .
Refer to INSTALLING ACOUSTIC COVER .
Refer to INSTALLING THE STIFFENING PLATE .
Refer to INSTALLING FRONT UNDERBODY PROTECTION .
Refer to CONNECTING ALL BATTERY GROUND LEADS .
Refer to CHECKING ENGINE OIL LEVEL .