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PostPosted: Sat Nov 16, 2019 9:59 pm 
Active user

Joined: Sat Oct 08, 2016 7:08 pm
Posts: 34
Car Models: 9-3
Hi all,
I did an oil change on my 2004 9-3 Aero (210bhp) today, and while I was under there, I noticed not one but two separate oil leaks. The first seems to be coming from the pulley side crankshaft oil seal. I was aware of this leak previously but it seems to be getting worse. I think I'm going to have to bite the bullet and replace the seal. After a bit of googling it looks like this is fairly doable, just a matter of removing the arch liner and engine mount, then dropping the engine a bit, removing the pulley, and replacing the seal. I have two questions though.
1. Do I need to remove the timing case for this, and if so then I assume I'll need a new gasket?
2. Can I reuse the pulley bolt or do I need to replace it (And what should the bolt be torqued to?)

The second leak seems to dripping down out of the bell housing. It looks like engine oil, but I wanted to check the gearbox oil level. After some googling it looks like the six speed gearbox doesn't have a level bung, is that correct? People seem to be saying that the gearbox oil is a distinctive red colour, but is that likely to still be true after 110k miles? Finally (sorry I've so many questions :oops: ), is there anything to be aware of when replacing the flywheel side crank seal or is it fairly straightforward?

PostPosted: Sun Jan 05, 2020 4:59 pm 
Active user

Joined: Sat Oct 08, 2016 7:08 pm
Posts: 34
Car Models: 9-3
So, an update in case anyone is interested!
I went ahead and replaced the timing chain side crank seal. It definitely seemed to be leaking, the was oil sprayed all around it. I removed the wheel arch liner for access, but then to get at the aux belt tensioner to remove the belt I had to remove the air box and engine mount. Jacking the engine up allowed me to remove the aux belt, and dropping it down allowed me on to the pulley bolt with socket. Very straightforward job, I removed the pulley, then the old seal, replaced the seal, and then the pulley. I reused the old bolt and simply tightened it up with an impact wrench as I didn't have a torque figure.
I noticed that the flange on the pulley has a small groove worn into it by the seal, so ideally I'd have replaced it too, but I think a new seal seems to have solved the problem for now.

I'm in two minds about the gearbox side oil leak, I think now it might be running down the back of the engine and onto the bottom of the bell housing. Will have to investigate further.

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