Removing and Installing Crankshaft
Removing and installing crankshaftPreliminary work
1. Remove pistons.
2. Remove front crankshaft belt pulley.
3. Remove timing chains.
Information
Component overview
Crankshaft Component Overview:
Crankshaft Attachments:
Removing crankshaft
ATTENTION: Damage to sensitive engine components (e.g. speed sensor wheel)
--> Conscientious and precise work
--> Use suitable storage places.
Sealing Flange Fastening Screws:
Levering Off Sealing Flange:
1. Remove the sealing flange at the front behind the belt pulley. Do this by removing all the fastening screws and carefully levering out the sealing flange. Clean sealing surfaces.
Note:
^ Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.
^ Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
^ The twist locks or retaining lugs are on the same side.
^ Bearing screws must be replaced.
^ Bearing shells must be replaced. Use only identical color markings
2. Dismantle all bearing covers from the crankshaft. Bearing covers and shells are assigned to specific cylinders and should be set aside on a clean surface where they will not get mixed up. For bearing cover no. 5, carefully remove the thrust washers at the side.
ATTENTION: Risk of cutting or squashing by heavy components with sharp edges (crankshaft)!
^ There is a danger of injury to hands when inserting the crankshaft.
--> Hold the very outside of the crankshaft.
--> Wear gloves.
--> Allow an assistant to help lift the crankshaft.
Note: Prepare a suitable storage space for the crankshaft so that the speed sensor wheel is not damaged.
3. With the help of assistants, carefully lift the crankshaft out of the cylinder block and set aside on a soft, clean surface so that the sensor wheel is not damaged.
Installing crankshaft
1. Replace bearing shells and thrust washers. When replacing bearing shells make sure that the color markings match.
Twist Locks:
2. Insert bearing shells into the bearings and bearing covers after oiling them. Insert twist locks or retaining lugs for the bearing shells into the recesses. Make sure the twist locks are positioned correctly --> Twist locks.
ATTENTION: Risk of cutting or squashing by heavy components with sharp edges (crankshaft)!
^ There is a danger of injury to hands when inserting the crankshaft.
--> Hold the very outside of the crankshaft.
--> Wear gloves.
--> Allow an assistant to help lift the crankshaft.
3. Carefully insert the crankshaft into the cylinder block with the help of an assistant. Test once again that the bearing shells and thrust washers are correctly positioned (they can easily shift out of place). Oil crankshaft journals.
Note:
^ Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.
^ Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
^ The twist locks or retaining lugs are on the same side.
^ Bearing screws must be replaced.
^ Bearing shells must be replaced. Use only identical color markings
4. Replace fastening screws for bearing covers. Attach all bearing covers to the crankshaft. Bearing covers and shells should be oiled and installed so that the twist locks or retaining lugs are on the same side.
5. Insert sickle-shaped washers into bearing cover no. 5 (make sure there is axial play in the bearings). Insert the two sickle-shaped washers (thrust washers) to the left and right of bearing cover no. 5 with a certain amount of grease so that the washers do not fall down. Each of the lubricating grooves of the sickle-shaped washers must face outwards. Assemble bearing cover no. 5 along with the greased thrust washers.
6. Pull out all the bearing cover fastening screws diagonally outward from the middle Initial tightening 22 ft. lbs.. Final tightening 180°.
Note: Lubricant must be applied thinly to the inside of the bore.
Application Sealant To The Sealing Flange:
Front Sealing Flange:
7. Attach the sealing flange at the front behind the belt pulley. Clean sealing surfaces. Apply Silicon 000.040.300.33 sealant thinly and evenly on the sealing surfaces of the sealing flange. Attach sealing flange immediately and tighten fastening screws. Tighten fastening screws evenly. Tightening torque 7.5 ft. lbs..
Replacing speed sensor wheel
Replacing pick-up (sensor) wheel
1. Remove the crankshaft and set it aside so that the speed sensor wheel is easily accessible and is not in contact with the shaft.
Speed Sensor Wheel:
2. Loosen the fastening screws -1 and 2-. Carefully remove the speed sensor wheel.
3. Clean the attachment surfaces Smear the attachment surfaces thinly with medium locking agent.
4. Immediately position a new speed sensor wheel on the crankshaft and align it. Align the VR6 marking to the individual bore on the crankshaft. Apply medium-tight screw locking agent to all fastening screws with and tighten the screws hand-tight. Tighten the fastening screw -1- first. Insert Initial tightening 7.5 ft. lbs. Insert Final tightening 90° Then tighten the screw -2- firmly. Insert Initial tightening 7.5 ft. lbs.. Insert Final tightening 90°.
5. Install crankshaft.
Gap In The Teeth Of The Speed Sensor Wheel:
Worn Drive Gear Tooth -B- To Bearing Joint Face (Shown With Timing Chains Fitted):
6. Check whether the gap in the teeth of the speed sensor wheel points downwards in the top dead centre position -arrow-. At the same time, the ground tooth of the crankshaft sprocket must align with the joint face of the bearing cover -B-.
Subsequent work
1. Replace sealing ring on pulley.
2. Install pistons.
3. Fit timing chains.