Camshaft Oil Seal: Service and Repair

NOTE: Special Tools Required: 5284, 5025, 5034.




PRELIMINARY CHECKS:
1. Check that flame guard is not blocked. A blocked flame guard prevents crankcase ventilation from operating properly. Crankcase pressure will be too high.


NOTE: Flame guard should not be installed on turbo engines.

2. Symptoms of a blocked flame guard are:
- oil dipstick pops up of pipe.
- oil leaks from oil seals in cylinder block. The oil seals need not always be replaced if they leak due to a blocked flame guard. Clean flame guard and engine and recheck seals for leakage
- engine knocks.







REMOVAL PROCEDURE:
Disconnect/Remove:
1. Disconnect battery ground cable.
2. Remove cooling fan.
3. Remove clamp for preheating hose below fan shroud (optional).
4. Remove fan shroud.
5. Remove drive belts and coolant pump pulley:
- loosen adjustments.
- remove AC compressor and alternator belts.
- remove pulley.
6. Remove upper timing belt cover:
- 1 10 mm socket M 6 bolt
- 2 12 mm socket M 8 bolt
- 3 Phillips screwdriver sheet metal screws




Check Basic Settings:
1. Use center bolt to turn crankshaft.
2. Set camshaft so that marking on pulley is opposite marking on inner timing belt cover and crankshaft marking opposite 0 on cover.
3. Remove cap distributor and check that rotor points opposite marking.




Remove Vibration Damper:
1. Remove nut and washer from timing belt tensioner.
2. Install tool 5284. Use nut to retain it.
3. Remove bolt for vibration damper. Remove tool 5284.
4. Check/adjust 0 marking.
5. Remove vibration damper.







Remove Timing Belt:
1. Remove lower timing belt cover.
- 1 10 mm socket M 6 bolt
- 2 12 mm socket M 8 bolt
2. Pull on timing belt to depress belt tensioner spring and lock it with a 3 mm drill.
3. Remove timing belt.

CAUTION: Do not turn crankshaft or camshaft. Pistons may strike valves.










Camshaft and/or Intermediate Shaft Seal Removal:
1. Check which seal is leaking.
2. Remove Pulley at seal to be replaced. Use tool 5034.
3. Remove timing belt tensioner. Pull straight out.
4. Remove inner timing belt cover.
5. Remove seal to be replaced. Carefully pry loose seal with a screwdriver. The contact face must not become damaged.
6. Clean and check contact faces for scoring and other damages.







INSTALLATION PROCEDURE:
Camshaft and/or Intermediate Shaft Seal Installation:
1. Grease seal and seat.
2. Install new seal. Use sleeve 5025 and press in seal.

Note: Make sure seal is not distorted or damaged during fitting.

3. Install inner timing belt cover.
4. Install timing belt tensioner.
5. Install pulleys as applicable:
- Position guide plates of camshaft pulley so that they incline outwards from pulley.
- Position intermediate shaft pulley with marking (a cavity) outwards.
- Hold pulley using tool 5034.
- Torque to 50 Nm (36 ft lbs).




Install Timing Belt:
1. Check Basic Settings.

CAUTION: Do not turn crankshaft or camshaft. Pistons may strike valves.

2. Position pulley according to marking.
3. Install timing belt on crankshaft and camshaft. Two lines on timing belt should be opposite crankshaft marking.
4. Stretch timing belt and install it on camshaft and belt tensioner.
5. Make sure timing belt is correctly positioned and that pulley markings are opposite markings on engine.
6. Install lower timing belt cover.




Install Vibration Damper:
1. Use counterhold 5284.
2. Torque crankshaft center bolt.
- Stage 1 60 Nm (45 ft lbs).
- Stage 2 Angle-tighten 60°.




Tension Timing Belt:
1. Install nut and washer for belt tensioner finger tight.
2. Pull timing belt to depress belt tensioner and remove locking drill.
3. Tensioner spring will now tension timing belt.
4. Tighten tensioner nut.




Reconnect/Reinstall:
1. upper timing belt cover.
2. pulley.
3. drive belts loosely.
4. fan shroud.
5. clamp for preheating hose.
6. cooling fan.
7. battery ground cable.
8. Tension drive belts:
- With correct tension, it should be possible to depress belt 510 mm (0.2-0.4 in) by thumb pressure.




Final Checks/Adjustments:
1. Run engine warm and check/adjust:
- ignition timing
- CO
- idle speed
- for leakages
2. Switch off engine.
3. Rotate engine until at top dead center.
4. Remove rubber plug on timing belt cover.
5. Loosen belt tensioner nut approx 1 turn.
6. Tensioner spring will not tension timing belt.
7. Tighten tensioner nut.
8. Install rubber plug.
9. After driving approx. 1000 km - 600 miles: Tension timing belt.