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Puma 1998 (06.1997-12.2001)

Engine - 1.7L - Crankshaft Front Seal Puma 1998 (06/1997-12/2001)
In-vehicle Repair

Special Tool(s)

Universal Flange Holding Wrench

205–072 (15-030A)

Remover, Crankshaft Seal

303-293 (21-143)

Alignment Plate, Camshaft

303-376 (21-162B)

Installer, Crankshaft Seal

303-395 (21-171)

Crankshaft TDC setting

303-507 (21-210)

Installer, Crankshaft Vibration Damper

303-510 (21-214)

Remover, crankshaft vibration damper

303-511 (21-215)

Pliers, spark plug connector

303-622 (21-226)
General Equipment
4,8 mm timing pin
Socket insert for E18 inner Torx bolts
Socket insert for T55 outer Torx bolts
Materials
Name
Specification
Grease
WSD-M1227-A 
Silicone grease
A960-M1C171-AA 

Removal

  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the cover plate from the cylinder head cover.

  1. Unscrew the upper bolt from the power steering pump bracket.

  1. Pull off the positive crankcase ventilation hose.
    1. Open the wiring harness cover.
    1. Disconnect the hose.

  1. Separate the connectors.
    1. Disconnect the variable camshaft timing (VCT) solenoid valve connector.
    1. Disconnect the camshaft position (CMP) sensor connector.
    1. Unlatch the injector rail, disconnect it and lay it to one side.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the drive belt cover.

  1. Slacken and remove the drive belt.

  1. Detach the coolant pump pulley and the idler pulley.

  1. Detach the bracket for the power steering line.
    • Detach the power steering line from the bracket.

  1. Remove the timing belt cover.
    • Remove the lower bolts (shown on an engine removed from the vehicle).
  1. Lower the vehicle.

  1. Remove the timing belt cover.
    • Undo the upper bolts.

  1. CAUTION:
    CAUTION:Do not pull the cable when removing the spark plug connectors. - remove the ignition cable from the ignition coil to avoid kinking the cable. Turn the spark plug connector slightly before detaching it in order to loosen the seal.
    CAUTION:
    CAUTION:Pull off the spark plug connectors in line with the spark plugs (for angled spark plug connectors use Special Tool 303-622).
    Detach the cylinder head cover (shown on an engine removed from the vehicle).
    • Remove the CMP sensor.
    • Carefully take out the rubber seal.
    • Pull off the spark plug connectors.
    • Unclip the ignition cables.

  1. Detach the EI ignition coil and the engine lifting eye.

  1. Set the engine to TDC on cylinder no.1.
    • Turn the engine using the crankshaft pulley/vibration damper until the special tool can be inserted.

  1. CAUTION:
    CAUTION:Do not undo the camshaft timing pulleys against the special tool.
    CAUTION:
    CAUTION:Only hold the camshafts by the hexagon with a spanner.
    Undo the camshaft timing pulleys (shown on an engine removed from the vehicle).
    • Loosen the camshaft pulley bolts so that the camshaft pulleys can turn freely on the camshafts (exhaust side shown).
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Detach the crankshaft pulley/vibration damper.
    • Lubricate the Special Tool 303-511 and bolts (M8 x 40) with grease.
    • Attach the special tool to the crankshaft pulley/vibration damper using two M8 x 40 bolts.
    • Pull the crankshaft pulley/vibration damper off the crankshaft by unscrewing the crankshaft pulley/vibration damper bolt.

  1. Slacken the timing belt.
    • Remove the retaining bolt.

  1. NOTE:
    NOTE:Installation position of the thrust washer
    Remove the lower timing belt cover.
    • Take off the thrust washer.

  1. Remove the timing belt guard and take the timing belt off the crankshaft timing pulley.

  1. Remove the oil seal using the special tool.

Installation
  1. Install the oil seal using the special tool.

  1. NOTE:
    NOTE:The arrows on the timing belt run clockwise.
    Lay the timing belt in place and install the timing belt guard.

  1. Adjust the timing belt tensioner.
    • Pull the 4,8 mm timing pin approx. 2 - 3 mm out until the spring is released and tensions the timing belt.
    • Tighten the adjustment bolt.
    • Slacken the timing belt tensioner and completely withdraw the 4,8 mm timing pin.

  1. NOTE:
    NOTE:Installation position of the thrust washer
    Slide on the thrust washer and attach the lower timing belt cover.

  1. Put the crankshaft pulley/vibration damper on the crankshaft and pull it home.

  1. NOTE:
    NOTE:Use a new bolt.
    Tighten the crankshaft pulley/vibration damper bolt.
    • 1st stage: 40 Nm
    • 2nd stage: 90 degrees

  1. NOTE:
    NOTE:If the special tool cannot be screwed in, turn the crankshaft back anti-clockwise by about 20 degrees.
    Set the crankshaft to TDC on cylinder no. 1.
    • Unscrew the blanking plug from the alignment pin bore hole and screw in the special tool.
    • Carefully turn the crankshaft clockwise until the crankshaft web meets the special tool.
    • Remove the Special Tool.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Only hold the camshafts by the hexagon with a spanner.
    Tighten the camshaft timing pulleys (shown on an engine removed from the vehicle).
    • Remove the special tool. **(303-376)**

  1. Check the valve timing.
    • Turn the crankshaft clockwise through two revolutions to TDC.
    • Set the crankshaft to TDC on cylinder no. 1.
    • Check the TDC position using the special tool.
    • Detach both special tools.
  1. NOTE:
    NOTE:Only if Special Tool 303-376 cannot be inserted.
    Check the valve timing.
    • Undo the affected camshaft timing pulley.
    • Turn the camshaft until Special Tool 303-276 can be inserted.
    • Tighten the camshaft timing pulley, in doing so the crankshaft must remain at TDC.
    • Check the valve timing again.

  1. Screw in the blanking cap (shown on an engine removed from the vehicle).

  1. Attach the EI ignition coil and the engine lifting eye.

  1. CAUTION:
    CAUTION:Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Slide on the spark plug connector keeping it in line with the spark plug.
    NOTE:
    NOTE:Grease the inside of the spark plug connectors.
    Attach the cylinder head cover (shown on an engine removed from the vehicle).
    • Install the CMP sensor.
    • Insert the rubber seal.
    • Coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.
    • Push on the spark plug connectors.
    • Clip the ignition cables in place.

  1. Install the timing belt cover.
    • Screw in the upper bolts.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Screw the blanking plug into the alignment pin bore hole.

  1. Install the timing belt cover.
    • Screw in the lower bolt (shown on an engine removed from the vehicle).

  1. Attach the bracket for the power steering pump.
    • Attach the power steering line to the bracket.

  1. Attach the coolant pump pulley and the idler pulley.

  1. Fit and tension the drive belt.

  1. Fit the drive belt cover.
  1. Lower the vehicle.

  1. Join the connectors.
    1. Connect the VCT solenoid valve connector.
    1. Connect the CMP sensor connector.
    1. Connect the injector rail.

  1. Push on the positive crankcase ventilation hose.
    1. Push on the hose.
    1. Close the wiring harness cover.

  1. Screw in the upper bolt on the power steering pump bracket.

  1. NOTE:
    NOTE:Fit all of the bolts loosely, centre the cover and tighten the bolts to the specified torque.
    Fit the cover plate onto the cylinder head cover.
  1. Standard finishing operations.
    • Connect battery ground cable.
      For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
    • - Secure the cables with cable ties.

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