Disassembling and Assembling Crankshaft
Disassembling and assembling crankshaft
Preliminary Work
1. Remove engine.
2. Remove transmission.
3. Disassemble engine as far as the crankcase.
4. Remove crankshaft.
Disassembling crankshaft
Caution
Risk of damage due to particles of dirt.
^ Danger of material damage due to blocked oil bores/oil ducts.
- Absolute cleanliness is essential when working on the engine.
- Lay removed engine parts on a clean base and make sure to cover them.
- Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Component overview
Component overview for crankshaft - connecting rod
1. Pull off roll pin (6 x 16) on crankshaft flange (flywheel side) using a vice-grip wrench.
2. Fit special tool retainer plate P209a, on crankshaft flange (flywheel side) with three cheese head bolts.
Crankshaft with retainer plate P209 a
3. Clamp crankshaft in a vice using the retainer plate P209a.
4. Loosen connecting rod bolts (multiple-tooth collar nut) with a socket wrench insert. Take off connecting rod and connecting-rod bearing cap.
5. Remove old connecting-rod bearing shells.
Information
^ Before assembly, make sure to check the elongation of the connecting rod bolts. If the dimension X (38.3 mm) is exceeded, the bolts must be replaced in accordance with the description for installation and removal.
6. Measure the length of the connecting rod bolts. To do this, determine the permitted length of the bolt using a depth gauge. - Nominal value: 38.3 mm
Length of connecting rod bolt
7. Remove circlip on the intermediate ring with circlip pliers.
Circlip on crankshaft bearing
8. Remove spacer ring and timing gear with a conventional puller.
9. Raise Woodruff key with side cutters and remove it.
10. Remove crankshaft from the retainer plate and clean it carefully (e.g. with solvent naphtha).
11. Rinse out lubrication bores on the crankshaft several times with solvent naphtha and blow out with compressed air.
12. Check bearings on crankshaft (main bearing and connecting-rod bearing) for signs of damage and wear.
Replacing connecting rod bolts
Caution
Pressing connecting rod bolts out and in.
^ Risk of damaging the connecting-rod cap.
^ Risk of subsequent engine damage.
- Insert aluminium or plastic clamping jaws on the vice.
- Use an aluminium sleeve (e.g. from special tool set P140, threaded sleeve for cylinder) for pressing bolts in.
1. Clamp the connecting-rod cap in a mechanical vice. Press the two connecting rod bolts out at the same time.
Pressing out connecting rod bolts
2. Guide the new connecting rod bolt by hand into the toothing and then press it in as far as the mounting face. Use the aluminium sleeve from the set of retaining nuts P140.
Pressing in connecting rod bolt
3. Allocate the connecting-rod cap and connecting rod according to matching number and have them ready for installation.
Matching number for connecting-rod cap and connecting rod
Assembling crankshaft
Caution
Risk of damage due to particles of dirt.
^ Danger of material damage due to blocked oil bores/oil ducts.
- Absolute cleanliness is essential when working on the engine.
- Lay removed engine parts on a clean base and make sure to cover them.
- Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
1. Clamp crankshaft in a vice using the retainer plate P209a.
2. Sputtered bearing shells are used on the connecting rods. These have two locking lugs to differentiate them and to avoid confusion.
Sputtered bearing shell on connecting rod
3. Conventional bearing shells with one retaining lug are fitted on the connecting-rod caps.
Bearing shell on connecting-rod cap
Information
Fit the connecting rods in such a way that the matching numbers are all facing the observer.
4. Lubricate the con-rod journals with grease (Optimol Optipit) and fit the connecting rods on the crankshaft.
Greasing con-rod journals
Matching number on con-rod assembly
5. Tighten connecting rod nuts to the prescribed tightening torque.
6. After the tightening procedure, check that the connecting rod bolt is not twisted. - Initial tightening: 30 Nm (22 ftlb.); - Torque angle: 90°±2°.
Checking connecting rod bolt for twisting
7. Insert and align new Woodruff key for timing gear.
Information
^ The collar of the timing gear must point to bearing 7.
8. Heat timing gear to approx. 150 - 200°C on a heating plate. Remove timing gear from the heat source with a piston restraining strap and quickly fit or slide it into place on the crankshaft journal.
Fitting timing gear
9. Heat the intermediate ring in the same way and slide it on as far as it will go.
Information
^ The circlip must be inserted without play.
10. Select the required circlip by performing an insertion test.
11. The opening on the circlip should lie opposite the Woodruff key groove.
Circlip on crankshaft
12. Tap the circlip into the retaining groove with a blunt chisel.
Tapping in circlip
Subsequent Work
1. Install crankshaft.
2. Assemble engine - starting with the crankcase.
3. Refit the transmission.