Crankshaft
Removing and installing crankshaft
Preliminary Work
1. Remove engine.
2. Remove transmission.
3. Disassemble engine as far as the cylinder housing.
4. Remove pistons.
Removing crankshaft
Component overview for crankcase
Overview of crankcase 1-3 (symbolic representation)
Crankcase half 1-3
Overview of crankcase 4-6
Crankcase half 4-6
Removing 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.
Caution
Removing/fitting the crankshaft pulley.
^ Danger of injury and damage.
- The holding wrench must make contact with the pulley when tightening.
- Get another person to help.
1. Loosen pulley. To do this, a second person should counter with the holding wrench 9548 at the same time. Do not continue to use the hexagon-head bolt.
Loosening the pulley
2. Loosen the 18 hexagon nuts (M8) on the crankcase cross bolt connection.
3. Loosen the two short through bolts on side 4-6 (flywheel side).
Through bolts on flywheel side
4. Loosen the fastening nuts (hexagon -1- and multiple-tooth -2-) on and in the chain box (cylinder row 1-3).
Cross bolt connection on chain box
5. Loosen through bolts from the outside to the inside.
Loosening through bolts
6. Pull off through bolts.
Pulling off through bolts
Information
^ The through bolts in thrust blocks 2, 3, 4 and 5 -Arrows- can only be removed after lifting off crankcase half 1-3.
7. Lift off crankcase half 1-3.
8. Remove O-rings and through bolts on thrust blocks -2,3,4 and 5-.
O-rings and inner through bolts
Installing 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. Secure engine support support P201 on crankcase half 4-6.
2. Check the matching number of the crankcase halves. The number is located on the top of the head lug.
Marking on crankcase halves
3. Allocation of the crankshaft gearwheel and 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.
Matching number on crankcase
Matching number on crankshaft gearwheel
Matching number on intermediate shaft gearwheel
4. Clean the crankcase halves thoroughly. Check whether there are any foreign objects (e.g. residual sealant) in the take-up bores of the through bolts.
5. Insert new bearing shells for the intermediate shaft in crankcase half 4-6.
Bearing shells 4-6 for intermediate shaft
6. Oil bearing shells for intermediate shaft, insert intermediate shaft and check for true running.
Checking intermediate shaft visually for true running
7. Insert new crankshaft bearing shells into the crankcase. Oil the bearings.
8. Check that dowel sleeves are seated correctly.
Dowel sleeves on crankcase
9. Insert crankshaft (without bearing 8) into crankcase half 4-6.
Information
^ If the wear dimension has been attained, replace the intermediate shaft and the paired drive wheel
10. Check backlash on intermediate shaft. To do this, secure the dial gauge holder VW 387 on the crankcase joint. The sealing surface must not be damaged during this procedure. Align the dial gauge on a tooth profile and determine the amount of play. Then turn the intermediate shaft by 180 and repeat the measurement.
Checking backlash on intermediate shaft
11. Remove intermediate shaft again.
12. Get another person to lift the crankshaft slightly and slide bearing No. 8 onto the crankshaft journal.
13. Lower the crankshaft slowly and insert crankshaft bearing No. 8 into the dowel pin.
Fitting crankshaft bearing 8
14. Check installation position. If the position is correct, the center of the bearing notch should be on the same level as the sealing surface.
Installation position of crankshaft
15. Fit shaft sealing ring on the crankshaft flange.
New crankshaft sealing ring
Information
Always replace gaskets and O-rings.
Information
Use Kluber grease (Syntheso glep, Part No. 000.043.204.68 for all lubrication points.
16. Grease new sealing ring (19.5 x 26) on both sides and insert it into crankcase half 4-6 close to the oil pump mount.
Sealing ring on oil pump mount
17. Insert oil pump with connecting shaft and intermediate shaft with both timing chains into the crankcase half.
Information
^ Always replace fastening nuts
18. Fit and tighten three new M8 fastening nuts. - Tightening torque: 23 Nm (17 ftlb.)
Collar nuts on oil pump
19. Check connecting shaft. The connecting shaft must move freely in axial direction. Loosen the oil pump with intermediate shaft again if necessary and shift the connecting shaft.
Connecting shaft between oil pump and intermediate shaft
20. Prepare the through bolts for installation. The diagram shows the through bolts already fitted on the designated thrust blocks.
O-rings and inner through bolts
Information
^ Additional O-rings are inserted on four through bolts on the thrust block mount, thrust blocks 2, 3, 4 and 5.
^ The four through bolts must be fitted before joining the crankcase halves.
Information
^ Do not oil sealing rings until shortly before fitting.
^ Do not store oiled sealing rings.
21. Prepare four through bolts. Slide sealing washers onto the through bolts. Guide lightly oiled O-rings with conical sleeve from special tool assembly sleeve 9511 over the threaded area and push them on to the conical section towards the head of the bolt.
Preparing through bolts for assembly
22. Observe the A and B side on the assembly sleeve 9511.
Special tool assembly sleeve 9511
23. Insert the prepared through bolts as far as they will go into the right crankcase half from below and hold at this position.
Inserting through bolts
24. Fit conical sleeve on the end of the thread. Slide dry O-ring 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.
Setting conical sleeve for assembling through bolts
Using the conical sleeve
25. Lift connecting rod of cylinder 4, 5 and 6 using special tool restraining straps P221. Lift timing chain with restraining strap.
Placing connecting rod in a vertical position
26. Coat two new sealing rings on the oil pump and the new sealing ring on the crankcase half with Kluber grease and insert them.
Sealing ring on oil pump
27. Prepare crankcase halves of cylinder row 1-3. To do this, insert the bearing shells of the crankshaft and the intermediate shaft. Be careful with the dowel pin -Arrow-.
Preparing crankcase 1-3 for installation
28. Remove any grease from the crankcase halves using acetone or solvent naphtha. Apply a uniform bead of sealant approximately 1.5 mm wide to the sealing face of crankcase half 1-3. Use Drei Bond, type 2210 sealant.
Applying sealant to crankcase halves
29. Check the relief groove close to main bearing No. 7 for foreign objects (e.g. silicone residue) and clean it if necessary.
Relief groove on main bearing 7
Information
^ Cover the chain slot briefly when fitting so that parts do not fall into the crankcase.
30. Insert the crankcase half carefully over the preassembled through bolts on thrust blocks 2, 3, 4 and 5, while at the same time getting another person to pull the chain upwards through the chain slot.
31. Remove restraining straps again.
32. Join the crankcase halves and secure them with six new lock nuts with washers. Distribute the lock nuts evenly all around the joint and tighten by hand.
Lock nuts on cross bolt connection
33. Insert the prepared through bolts for crankcase half 4-6 and hold them securely.
Inserting through bolts
34. Slide the conical sleeve of special tool assembly sleeve 9511 with an oiled O-ring to the end of the thread.
Inserting conical sleeve with oiled sealing ring
35. Slide the O-ring carefully over the conical sleeve with the -A-side- of the cylinder sleeve (thin wall).
Special tool assembly sleeve 9511
Fitting O-ring for through bolt
36. Remove conical sleeve and carefully slide the round sealing ring to its end position with the B-side of the cylinder sleeve (thick wall), while countering at the bolt head.
37. Fit dry sealing washers and press downwards slightly with the B-side of the cylinder sleeve.
38. Screw on outer multiple-tooth nuts (thread oiled) by hand.
39. Proceed in the same way with both studs on crankcase half 4-6 (bearing 1 area) on the flywheel side.
40. Screw M10 multiple-tooth nut onto stud (thread oiled) in the chain box.
Hexagon nut in chain box
Information
^ When tightening the through bolts without a retaining device 9662, it is essential that a second person counters the bolts.
^ The O-ring will be damaged when the through bolts are turned.
^ Counter using a 14 mm multiple-tooth socket from Snap-on.
41. Retaining device 9662 must be fitted on the corresponding through bolt and can then be positioned using an aluminium sleeve from the set of retaining nuts P140.
Retaining device 9662
42. Bolt crankcase halves.
42.1. Tighten through bolts on side 1-3 -1-11- according to tightening sequence and specifications (see table below).
Tightening sequence for through bolts
M10 multiple-tooth nut in chain box
42.2. Tighten M10 multiple-tooth nut -12- on stud in chain box side 1-3.
Through bolts on flywheel side
42.3. Tighten through bolts on flywheel side on side 4-6.
42.4. Tighten new self-locking hexagon nut with washer. - Tightening torque: 25 Nm (19 ftlb.)
Lock nuts on chain box
43. Fit remaining M8 lock nuts on crankcase bolts. - Tightening torque: 25 Nm (19 ftlb.)
Caution
Removing/fitting the crankshaft pulley.
^ Danger of injury and damage.
- The holding wrench must make contact with the pulley when tightening.
- Get another person to help.
44. Fit pulley. Check the straight pin (5 x 18) for deformation before fitting and replace if necessary.
Straight pin for pulley
45. Fit new straight pin so that it is flush.
Installation position of straight pin for pulley
46. Always replace fastening screw for pulley. When tightening the pulley, a second person must counter with the special tool holding wrench 9548. - Tightening torque: 170 Nm (126 ftlb.)
Tightening pulley
47. Fit flywheel.
Subsequent Work
1. Install pistons.
2. Assemble engine - starting with the cylinder housing.
3. Refit the transmission.
4. Install engine.