Disassembling and Assembling Crankcase

Disassembling and assembling crankshaft




















Tools

Disassembling crankshaft
1. Remove tensioning sleeve (6 x 16) with a vice-grip wrench.
2. Clamp retaining plate P 209 a in the vice.





3. Fasten the crankshaft to the retaining plate with 3 -pan-head screws- Part No. 928 102 151 01.
4. Loosen connecting rods with socket wrench insert M14 and remove.





5. Remove snap ring with snap ring pliers.
6. Remove spacer ring and timing gear with a conventional puller.
7. Lift Woodruff key with side cutters and remove.
8. Remove crankshaft from retaining plate.
9. Check crankshaft for eccentricity, cracks and wear.
10. Carry out sounding test.

Assembling crankshaft
1. Clean crankshaft thoroughly.
2. Rinse out oil bores several times with a hand pump and solvent naphtha.
3. With a visual inspection, check whether the oil ducts are blocked at the bearing surfaces and on the front face (aluminum plugs).
4. Clamp crankshaft.





5. Lubricate the connecting-rod journals with grease (Optimal Optipit) and fit connecting rods on the crankshaft.





Note;
- The matching numbers of the con-rods and the con-rod bearing caps must all point to the same side.

Note;
- Always coat con-rod bolts with special grease, Part No.: 000.043.300.12

Note;
- The con-rod bolts must not twist.

6. Tighten con-rod nuts.





7. After tightening, check whether the con-rod bolt has twisted.
8. Insert and align new Woodruff key for timing gear.

Note;
- The collar of the timing gear must point to bearing 7!





- As an assembly aid, remove the timing gear from the heat source, e.g. with a piston restraining strap, and quickly mount or push it into place on the journal.

9. Warm the timing gear to approximately 150 - 200°C in an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop.
10. Heat up the spacer ring in the same way and push it on up to the stop.
11. Mount snap ring.

Note;
- The snap ring must be inserted without play!





The following snap rings are available:





12. Select the corresponding snap ring using an insertion test.
13. The opening of the snap ring should be opposite the Woodruff key groove.








14. Tap snap ring into the retaining groove using a blunt chisel.