Crankcase Assembling
Assembling the crankcase.
1. Fasten engine holder P201 to the right crankcase half (cylinder bank 4-6).
2. Check the matching number of the crankcase halves. The number is located on the top of the head lug.
Note!
There are tolerance groups 0 and 1
3. Allocation of the crankshaft gearwheel and the intermediate shaft to the crankcase. The tolerance group number is imprinted on the crankcase -arrow- and must match the number on the intermediate shaft gearwheel and the crankshaft gearwheel.
Pairing number on crankcase
Pairing number on crankshaft gearwheel -arrow-
Pairing number on the intermediate shaft gearwheel -arrow-
4. Clean crankcase halves thoroughly. Check whether there are any foreign objects (e.g. residual sealant) in the receiving bores of the tension rod bolts.
5. Fit the mounting of the intermediate shaft. Insert new bearing shell halves in the crankcase half of the cylinder bank 4 - 6.
6. Oil the bearing surfaces. Insert intermediate shaft and check for true running.
7. Insert new crankshaft bearing shell halves into the crankcase. Oil the bearing surfaces.
8. Check that the dowel sleeves are present and seated properly.
9. Insert crankshaft (excluding mount 8) into the crankcase half of the cylinder bank 4 - 6.
Note!
If the wear dimension has been attained, replace the intermediate shaft and the paired drive wheel
10. Check the circumferential backlash of the intermediate shaft. To do this, fasten a gauge holder e.g. VW 387 to the crankcase parting surface. The sealing surface must not be damaged during this procedure. Align the dial guage on a tooth profile and determine play. Subsequently turn the intermediate shaft by 180° and repeat the measurement.
Circumferential backlash:
New dimension 0.035 - 0.084 mm
Wear dimension 0.10 mm
11. Remove intermediate shaft again.
12. Let a second person lift the crankshaft slightly and push bearing no.8 onto the crankshaft journal.
13. Lower the crankshaft slowly and insert crankshaft bearing no. 8 into the dowel pin.
14. Check installation position. If the mounting is correct, the centre of the bearing notch should be on the same level as the sealing surface.
Note!
Oil sealing lip
Insert crankshaft sealing ring in the crankcase.
15. Grease sealing ring (19.5 x 26) on both sides and insert it into the crankcase half 4 - 6 in the area of the oil pump mount.
16. Insert the complete unit, oil pump with dumb-bell shaft and intermediate shaft with both timing chains into the crankcase half.
17. Fasten new collar nuts (3 pieces). Tightening torque 23 Nm (17 ftlb.).
18. Check dumb-bell shaft. The dumb-bell shaft must be easily movable in axial direction. If necessary, re-loosen the oil pump with the intermediate shaft and shift the dumb-bell shaft.
Note!
^ Additional O-rings are inserted on 4 tension rod bolts of the thrust block fastening, thrust blocks 2, 3, 4 and 5.
^ The 4 tension rod bolts must be mounted before joining the crankcase halves.
19. Prepare the tension rod bolts for installation. The diagram shows the already mounted tension rod bolts in the designated thrust blocks.
Note!
^ Do not oil sealing rings until shortly before fitting.
^ Do not store oiled sealing rings.
- Prepare four tension rod bolts. Push sealing washers on to tension rod bolts. Feed lightly oiled 0-rings with conical sleeve from special tool 9511 over the threaded area and push them on to the tapered section towards the head of the bolt.
- Observe the A side and B side on the assembly sleeve 9511.
- Insert the prepared tension rod bolts into the right crankcase half from below as far as they will go and retain in this position.
- Place conical sleeve on end of the thread. Push O-ring (dry) over the conical sleeve. Remove conical sleeve and push the O-ring with the cylinder sleeve as far as the chamfer in the thrust block. Remove cylinder sleeve.
Cylinder sleeve application
20. Lift connecting rod of cylinder 4, 5 and 6 with restraining straps, special tool P221. Lift timing chain with tension strap.
21. Coat both sides of sealing rings on the oil pump (2 pieces) and the sealing ring on the crankcase half with vaseline and insert.
22. Prepare crankcase halves of the cylinder bank 1 - 3. To do this, insert the bearing shells of the crankshaft and the intermediate shaft.
- Degrease the sealing surface of the crankcase halves. Apply a uniform bead of silicone (Drei Bond Type 1209) approximately 1.5 mm wide to the sealing surface of the crankcase half of cylinder bank 1 - 3.
- Check the relief groove in the area of the main bearing no.7 for foreign objects, e.g. silicone residue and clean if necessary.
- Insert the crankcase half carefully over the preassembled tension rod bolts of thrust blocks 2, 3, 4 and 5, at the same time having a second person pull the chain upwards through the chain space.
23. Remove restraining straps again.
Note!
Always replace fastening nuts
24. Join crankcase halves and secure with approx. 6 new fastening nuts with washers. Distribute the fastening nuts evenly on the periphery and tighten by hand.
25. Insert the prepared tension rod bolts of the crankcase half 4 - 6 and hold.
26. Push the conical sleeve of special tool 9511 with an oiled O-ring to the end of the thread.
27. Push the O-ring carefully away from the conical sleeve with the A-side (thin wall) of the cylinder sleeve.
View of the conical sleeve
28. Remove conical sleeve and carefully push round seal to its end position with the B-side (thick wall) of the cylinder sleeve, while bracing the bolt head.
29. Mount sealing washers (dry) and press downwards slightly with B-side of cylinder sleeve.
30. Screw on outer multiple-tooth nuts (thread oiled) by hand.
31. Proceed in the same way with both studs of the crankcase half 4 - 6 (area of bearing 1) on the flywheel side.
Note!
Cover the chain space briefly when fitting so that parts do not fall into the crankcase.
32. Mount hexagon nut M10 x 1.25 and washer A10.5 on stud, with rounded side pointing towards the hexagon nut.
33. Mount retaining device, special tool 9662, on corresponding tension rod bolts and position with holder, special tool P140.
Note!
^ When tightening the tension rod bolts without a retaining device 9662, it is essential that a second person braces the bolts.
^ The O-ring is damaged when the tension rod bolts are turned.
^ Use a 14 mm multiple-tooth socket from Snap-on to counter.
Retaining device 9662
34. Tighten tension rod bolts or studs with 50 Nm (37 ftlb.). When doing so, observe the tightening sequence.
35. Tighten tension rod bolts onto the flywheel side to 50 Nm (37 ftlb.).
36. Fit new self-locking hexagon nut with washers and tighten to 50 Nm (37 ftlb.).
Note!
The self-locking nuts must always be replaced.
37. Fit remaining crankcase screw connections. Tighten the hexagon nuts to 23 Nm (17 ftlb.).
38. Fit belt pulley. Check the cylindrical pin (5 x 18) for deformation before fitting and replace if necessary.
39. Mount new cylindrical pin so that it is flush.
Caution!
Danger of injury
- The holding wrench must be in contact with the belt pulley when tightening.
40. Always replace fastening screw of the belt pulley. When tightening the belt pulley, a second person must counter with the special tool 9548. The belt pulley is tightened to 170 Nm (126 ftlb.).
41. Fit flywheel.
42. Check distance -Dimension X- between toothed ring and pulse sender and adjust if necessary. Dimension X 1.0 + 0.2 mm
43. Turn belt pulley or the crankshaft to TDC, cylinder 1 or 4.
44. Subsequently fit piston or cylinder.