Part 1
WM 134819 Removing and installing crankshaft on V6 DFI engines
Tools
Technical values
Preliminary work
Information
- Dispose of fluid in accordance with legal requirements.
Information
- Press the bottom chain tensioner together during removal because otherwise it will push out due to spring tensioning. Secure chain tensioner with a tie-wrap in tensioned state.
1. Remove the engine. -> 100119 Removing and installing 3.6-litre DFI engine - section on "Removing" 100119 Removing and Installing 3.6-Litre DFI Engine
2. Remove the transmission. -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing engine from transmission and mounting engine on transmission
3. Secure engine on mounting bracket. -> 1001IN Supporting V6 3.6-litre DFI engine on mounting bracket 1001IN Supporting V6 3.6 l DFI engine on the mounting bracket
4. Remove engine carrier eyebolt at the front and rear. -> 1001IN Lifting V6 3.6-litre DFI engine with a workshop crane 1001IN Lifting V6 3.6 l DFI engine with a workshop crane
5. Remove the engine wire harness. -> 97522100 Removing wire harness for engine (V6) 975219 Removing and installing wire harness for engine
6. Remove bar ignition modules. -> 282020 Removing and installing DFI bar ignition modules Service and Repair
7. Remove intake-air distributor. -> 244619 Removing and installing DFI intake-air distributor - section on "Removing" Removal and Replacement
8. Remove drive belt. -> 137819 Removing and installing drive belt on V6 DFI engines - section on "Removing" Service and Repair
9. Remove belt tensioner. -> 137319 Removing and installing belt tensioner on DFI engines - section on "Removing" Service and Repair
Belt tensioner
10. Remove cylinder head cover.-> 158219 Removing and installing cylinder head cover on V6 DFI engines Removal and Replacement
11. Remove flywheel/drive plate.
11.1. Remove dual-mass flywheel on vehicles with manual transmission. -> 136219 Removing and installing dual-mass flywheel - section on "Removing"
11.2. Remove drive plate on vehicles with automatic transmission. -> 136319 Removing and installing drive plate for torque converter
12. Remove oil pan. -> 175019 Removing and installing oil pan on V6 DFI engines - section on "Removing" Service and Repair
13. Remove upper and lower timing-case cover. -> 153319 Removing and installing timing-case cover on V6 DFI engines - section on "Removing" Service and Repair
14. Position crankshaft to the compression TDC for cylinder 1. -> 150502 Checking the timing on V6 DFI engines Testing and Inspection
15. Remove chain tensioner. -> 153619 Removing and installing chain tensioner on V6 DFI engines - section on "Removing" Service and Repair
16. Remove timing chains. -> 153519 Removing and installing timing chains on V6 DFI engines - section on "Removing" Service and Repair
17. Remove cylinder head. -> 157019 Removing and installing cylinder head on V6 DFI engines - section on "Removing" Removal and Replacement
18. Remove pistons. -> 131019 Removing and installing pistons on V6 DFI engines - section on "Removing" Removal and Replacement
19. Remove vibration balancer. -> 137619 Removing and installing vibration balancer (crankshaft pulley) on V6 DFI engines Removal and Replacement
Brace
20. Remove joint flange behind the vibration balancer.
Crankshaft joint flange
20.1. Unscrew hexagon-head bolts -3-.
20.2. Carefully lever off the joint flange -2- with a screwdriver.
Removing crankshaft
Information
Removal of crankshaft
Before removing the crankshaft, have a suitable tray ready so that the pulse-generating wheel is not damaged as a result of excessive contact.
The engine is secured on the engine support to facilitate assembly work.
When replacing bearing shells, only use bearing shells with the same colour coding.
1. Remove the crankshaft.
Crank drive on V6 DFI engine
1.1. Prepare a clean surface for laying down the crankshaft. Make sure not to damage the drive plate for the inductive pickup (speed sender) when laying down the crankshaft.
1.2. Remove crankshaft bearing covers -1- and lay them down arranged according to cylinder.
1.3. Dispose of thrust washers -4- and crankshaft bearing shells -3-.
1.4. Remove the crankshaft and lay it down on the prepared surface.
1.5. Remove oil spray jets -8- if necessary.
Installing crankshaft
1. Install the crankshaft.
Crank drive on V6 DFI engine
1.1. Oil bearing shells with engine oil and place them on the crankshaft/crankcase.
Twist locks
1.2. Always replace bearing shells. Observe relevant classification.
1.3. Fit thrust bearing no. 5 with thrust washers -4- (insert using grease, lubricating groove facing outwards) and then fit the remaining bearing covers.
1.4. Tap crankshaft bearing covers on securely as far as they will go using a rubber hammer so that the tightening torque will be accurate.
1.5. Internal serration screws on the crankshaft bearing covers -2- must always be replaced and screwed in by hand.
1.6. Then gradually tighten the bearing covers from the inside out to the specified torque -2-.
1.7. As a test, turn the crankshaft several times to check that it turns smoothly.
Replacing speed sender wheel
1. If the drive plate -6- for the inductive pickup (speed sender) was removed from the crankshaft, it must always be replaced. The drive plate must never be reused.
Crank drive on V6 DFI engine
2. Tighten the countersunk screws -7- on the drive plate to the specified tightening torque.
Subsequent work
CAUTION
Leaks due to components being at too low a temperature or at different temperatures!
- If components that are cold or at different temperatures are sealed together by the application of sealant, adhesion problems and leaks can arise due to the build-up of condensation water or component distortion.
-> Components must have reached at least 17°C throughout.
-> Components must not be too hot (distortion).
-> Spare parts that are stored in the cold or heat (strong sunlight), must be brought to room temperature or the same temperature as other parts before installation.
Information
- Detailed instructions for installing pistons must be observed at all times.
- The cast lugs, the twist lock (locking lugs) -1- and the flat side of the piston crown -2- are on the same side.
Arrangement of pistons and connecting rods
1. Install pistons. -> 131019 Removing and installing pistons on V6 DFI engines Removal and Replacement
Overview of piston/connecting rod
1.1. Pull dowel sleeve -arrow- out of the bore hole so that special tool funnel T10333 can be positioned flat on the cylinder block.
Dowel sleeve on cylinder block
1.2. Oil the piston well and insert it into the funnel.
1.3. Align all pistons so that the deep valve recesses -1 and 2- are facing the middle of the cylinder block and the arrows -3- on the pistons are facing the vibration damper.
Installation direction of pistons on V6 DFI engine
1.4. Position the piston funnel on the cylinder block and align it so that the high edge -arrow- is facing the middle of the cylinder block.
Positioning piston funnel on cylinder block
1.5. Slide piston fully into the cylinder bore.
1.5.1. Turn the crankshaft back and forth if necessary.
1.6. Insert dowel sleeves back into the bore holes -arrow-.
1.7. Oil connecting-rod bearing shells -5-.
Information
- Always replace the connecting-rod bearing shells and oil them before inserting them into the bearing covers.
- The connecting-rod big end and connecting-rod bearing caps must be aligned according to the cast lugs -B and C-. The retaining lugs of the connecting-rod bearing shells are on one side. Connecting-rod bearing caps are legible on alternate sides.
Twist lock
- Install connecting rod and connecting-rod bearing caps unrestrained. If necessary, remove them again, position the bearing caps by tapping lightly with a plastic hammer and then refit them.
1.8. Assign connecting rod bearing caps correctly and screw in the connecting rod bolts -7- by hand. When doing so, make sure that the locking lugs on the bearing shells are aligned.
1.9. Carefully tap the connecting rod bearing caps -6- with a plastic hammer until they are seated correctly so that the tightening torque will be accurate.
1.10. Tighten all connecting rod bearing screws -7- to the specified tightening torque.
1.11. Turn the crankshaft several times to check that it turns smoothly.
1.12. Align the crankshaft so that the gap -arrow- on the drive plate for the inductive pickup is facing downwards (rough TDC presetting).
Setting of drive plate for inductive pickup
2. Fit joint flange for vibration balancer. -> 137419 Removing and installing sealing ring for vibration balancer on DFI engines Removal and Replacement
Crankshaft joint flange
2.1. Apply a bead of sealant -arrows- with a thickness of 2 mm.
Applying sealant on joint flange
2.2. Fit assembly fixture T10215 (guide sleeve) -1- on the crank pin -3- to prevent damage to the vibration balancer joint flange.
2.3. Slide the joint flange -2- over the guide sleeve -1- until it is touching the cylinder block.
Joint flange on front of crankshaft
2.4. Tighten hexagon-head bolts -3- on joint flange -2- to the specified torque.
3. Fit vibration balancer for crankshaft. -> 137619 Removing and installing vibration balancer (crankshaft pulley) on V6 DFI engines Removal and Replacement
Brace
3.1. Tighten hexagon-head bolt on crankshaft vibration balancer => Initial tightening: 100 Nm (74 ftlb.) => Torque angle: 180°.
4. Position engine to the compression TDC of cylinder 1.
TDC marking on pulley and housing cover
5. If the oil retaining valve was removed during removal, fit a new sealing ring on the oil retaining valve before inserting it into the crankcase -arrow-.
Oil retaining valve
6. Install cylinder head. -> 157019 Removing and installing cylinder head on V6 DFI engines Removal and Replacement
Cylinder head
6.1. Thoroughly clean all sealing faces before assembly.
6.2. Cylinder head gasket must always be replaced.
6.3. Always observe tightening sequence (1-20) for cylinder-head screws -1-20- and tighten to the specified torque.
6.3.1. Tighten cylinder-head screws to an initial tightening torque of 15 Nm (11 ftlb.).
6.3.2. Tighten cylinder-head screws to 30 Nm (22 ftlb.).
6.3.3. Then tighten all cylinder-head screws a second time to 30 Nm (22 ftlb.).
6.3.4. And finally, tighten the cylinder-head screws to a torque angle of 180°.
7. Fit timing chains. -> 153519 Removing and installing timing chains on V6 DFI engines Service and Repair
Component overview of timing chains
7.1. Install timing chain housing.
Removing timing chain housing
7.2. Install chain tensioner. -> 153619 Removing and installing chain tensioner on V6 DFI engines Service and Repair
7.3. Install camshaft controllers. -> 158419 Removing and installing camshaft controller on V6 DFI engines Service and Repair
8. Check the timing. -> 150502 Checking the timing on V6 DFI engines Testing and Inspection
9. Fit upper and lower timing-case cover. -> 153319 Removing and installing timing-case cover on V6 DFI engines Service and Repair
9.1. Fit lower timing-case cover.
Crankshaft joint flange
9.2. Fit upper timing-case cover.
Removing and installing vacuum pump
Information