Engind front cover - r r

Operation 1020D17 · OIL SEALS ON CRANKSHAFT

Removing

- 1004D40 engine - position on stand and remove

- 1032B16 toothed timing belt - r r with engine removed

Remove the oil filter and the engine oil heat exchanger.

1. Undo the front and rear bolts (1a) for the crankcase sump using tool (1b).

2. Undo the side bolts (2a) for the crankcase sump using the tool (2b), bearing in mind that the rubber plugs in the metal casing have to be removed to reach the flywheel side bolts.

3. Remove the crankcase sump (3a).

To loosen the sump from the crankcase, hammer tool (3b) in between both parts, then use a screwdriver for leverage in the special projections at the side of the crankcase sump.

Removing

- 1004D40 engine - position on stand and remove

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

2. Undo the bolt (2a) and remove the single drive belt fixed guide pulley (2b).

3. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).

1. Fit the tool.

1. Undo the bolts (1a) and remove the timing drive belt guard (1b).

2. Loosen the timing belt tensioner nut.

3. Remove the toothed timing drive belt.

1. Undo the left bolt (1a) and remove the toothed drive pulley (1b).

1. Undo the bolts (1a) and remove the complete oil dipstick (1b).

2. Disconnect the condensation oil return pipe to the sump.

1. Undo the bolts (1a) and remove the crankcase front cover with built in oil pump (1b) and intake housing.

Remove the crankshaft front oil seal.

Rotate the engine through 180° on the overhauling stand.

1. Undo the front and rear bolts (1a) for the crankcase sump using tool (1b).

2. Undo the side bolts (2a) for the crankcase sump using tool (2b).

3. Remove the crankcase sump (3a).

To loosen the sump from the crankcase, insert tool (3b) between both components using a mallet, then use a screwdriver for leverage in the special projections at the side of the crankcase sump.

Refitting

Fit the engine block front cover complete with oil pump and intake housing without tightening the bolts.

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

1. Undo the bolts (1a) and remove the crankcase front cover with built in oil pump (1b) and intake housing.

Remove the crankshaft front oil seal.

Tighten the bolts for the crankcase front cover to torque.

Fit the water - oil heat exchanger and fix it using the pin.

Fit the oil filter.

Apply sealant to the entire perimeter of the crankcase sump.

Fit the crankcase sump.

Tighten the side bolts for the crankcase sump to torque using the tool.

Tighten the front and rear crankcase sump bolts to torque in a crossed pattern using tool.

Rotate the engine through 180° on the overhauling stand.

Fit the auxiliary shaft belt tensioner and fix it using the relevant bolt.

Fit the fixed timing belt tensioner and fix it using the relevant bolt.

Connect the water inlet and outlet pipes from the water - oil heat exchanger and secure using relevant collars.

1. Fit toothed drive pulley (1a) and tighten bolt (anticlockwise) (1b) to torque.

Refitting

Fit the engine block front cover complete with oil pump and intake housing without tightening the bolts.

1. Fit a new crankshaft front oil seal (1a) using the tool (1b).

Remove the tool.

Fit the oil filter and the engine oil heat exchanger.

- 1032B16 toothed timing belt - r r with engine removed

- 1004D40 engine - position on stand and remove

Tighten the bolts for the crankcase front cover to torque.

Fit the water - oil heat exchanger and fix it using the pin.

Fit the oil filter.

Apply sealant to the entire perimeter of the crankcase sump.

Fit the crankcase sump.

Tighten the side bolts for the crankcase sump to torque using the tool.

Tighten the front and rear bolts for the crankcase sump to torque using the tool.

Rotate the engine through 180° on the overhauling stand.

Connect the condensate oil return pipe to the crankcase sump and secure using a collar.

Fit the engine oil dipstick assembly and fix it using the bolts.

Fit the auxiliary shaft belt tensioner and fix it using the relevant bolt.

Fit the fixed timing belt tensioner and fix it using the relevant bolt.

Connect the water inlet and outlet pipes from the water - oil heat exchanger and secure using relevant collars.

Fit the power unit support, timing gear side, and fix it using the bolts.

1. Fit toothed drive pulley (1a) and tighten bolt (anticlockwise) (1b) to torque.

Remove the tool.

1. Remove the bolt for the oil pump shown.

Temporarily fit the single toothed timing drive belt to the drive pulley.

2. Fit the tool.

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

1. Rotate the driven pulley so that the timing references line up.

2. Completely fit the timing belt.

3. Use a screwdriver for leverage in the opening (3a) so that the reference on the tensioner (3b) is aligned with the opening reference (3c) and, in this position, tighten the belt tensioner nut (3d) to torque.

Remove the tool.

Rotate the crankshaft through two revolutions.

Check once again that the timing references and the tensioning references on the timing belt tensioner coincide.

Fit the timing drive belt guards and fix them using the bolts.

Fit the power unit reaction rod attachment bracket and fix it using the bolts.

Fit the engine component single drive belt guide pulley and fix it using the bolt.

Fit the crankshaft pulley.

Fit the single engine component belt by adjusting the automatic belt tensioner using a wrench.