11 21 505 Sealing crankcase lower section

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IMPORTANT: Aluminium-magnesium materials.

No steel screws/bolts may be used due to the threat of electrochemical corrosion.

A magnesium crankcase requires aluminum screws/bolts exclusively.

Aluminum screws/bolts must be replaced each time they are released.

Aluminum screws/bolts are permitted with and without color coding (blue).

For reliable identification:

Aluminum screws/bolts are not magnetic.

Risk of damage!

Jointing torque and angle of rotation must be observed without fail.

IMPORTANT: Changed procedure.

It is not necessary to remove the cylinder head and the crankshaft.

Necessary preliminary tasks:

Remove engine.
Mount engine on ASSEMBLY STAND .
Remove CLUTCH (if fitted).
Remove LEFT and RIGHT engine support arm.
Remove oil sump.

Release screws (1).

Pull out oil pump intake pipe (2).

Tightening torque:

ASA screw
Oil deflector to crankcase lower half.
Aluminium screws/bolts are permitted with and without color coding (blue).

M6 x 20

Replace screw.
Thread repairs exclusively with aluminium Helicoil threaded insert.
Jointing torque and angle of rotation must be observed without fail.

Jointing torque: 4 Nm
Angle of rotation: 90 °

Fig 1: Removing Pump Intake Pipe

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Release screws (1).

Tightening torque:

ASA screw
Oil deflector to crankcase lower half.
Aluminium screws/bolts are permitted with and without color coding (blue).

M6 x 20

Replace screw.
Thread repairs exclusively with aluminium Helicoil threaded insert.
Jointing torque and angle of rotation must be observed without fail.

Jointing torque: 4 Nm
Angle of rotation: 90 °

Installation note:

Replace aluminum screws.

Remove oil deflector (2).

Fig 2: Identifying Oil Deflector And Screws

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Secure oil pump drive gear with 6.0 mm dia. steel pin (3) to oil pump.

IMPORTANT: Release central bolt (2) only together with 6.0 mm dia. steel pin (3).

Do not remove sprocket.

Release central bolt (2).

Tightening torque:

Sprocket to oil pump

Jointing torque: 20 Nm
Angle of rotation: 45 °

Fig 3: Identifying Oil Pump Drive Gear And Steel Pin

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Unfasten screws (2).

Tightening torque:

Chain module to crankcase and oil pump

M6 x 16

Replace screws.
Thread repairs exclusively with aluminium Helicoil threaded insert.
Jointing torque and angle of rotation must be observed without fail.

Jointing torque: 4 Nm
Angle of rotation: 45 °

Installation note:

Replace aluminum screws.

Fig 4: Identifying Screws

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Remove screw plug (1) from crankcase at front.

NOTE: Replace gasket.

Fig 5: Identifying Screw Plug

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Release screw (1) for oil pump triangular drive with special tool 11 8 640 .

NOTE: It is not necessary to remove the triangular drive.

Fig 6: Identifying Oil Pump Triangular Drive Mounting Screw

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Version 1

IMPORTANT: Observe different screw lengths.

Release screws (1).

Tightening torque:

Oil pump to bedplate	M8 x 123	Replace screws. Thread repairs exclusively with aluminium Helicoil threaded insert. Jointing torque and angle of rotation must be observed without fail.	Jointing torque: 10 Nm Angle of rotation: 180 °
Oil pump to bedplate	M8 x 31	Replace screws. Thread repairs exclusively with aluminium Helicoil threaded insert. Jointing torque and angle of rotation must be observed without fail.	Jointing torque: 10 Nm Angle of rotation: 90 °

Installation note:

Replace aluminum screws.

Fig 7: Identifying Screws

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Version 2

IMPORTANT: Observe different screw lengths.

Release oil pump screws (1).

Tightening torque:

Oil pump to bedplate	M8 x 123	Replace screws. Thread repairs exclusively with aluminium Helicoil threaded insert. Jointing torque and angle of rotation must be observed without fail.	Jointing torque: 10 Nm Angle of rotation: 180 °
Oil pump to bedplate	M8 x 31	Replace screws. Thread repairs exclusively with aluminium Helicoil threaded insert. Jointing torque and angle of rotation must be observed without fail.	Jointing torque: 10 Nm Angle of rotation: 90 °

Installation note:

Replace aluminum screws.

Fig 8: Identifying Oil Pump Mounting Screws

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Detach sprocket (1) in direction of arrow.

NOTE: The chain tensioner pushes the timing chain (3) of the triangular drive upward.

Do not remove camshaft sprocket.

Remove oil pump (2) in direction of arrow.

Fig 9: Removing Sprocket

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Installation note:

Check spacer bushings (1) for secure seating and damage; replace if necessary.

Align twin surface (3) on oil pump (2) to sprocket wheel.

Install oil pump (2).

Fig 10: Identifying Spacer Bushings And Oil Pump

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NOTE: The dowel hole for the TDC setting is located on the intake side underneath the starter motor.

Rotate engine at central bolt and secure flywheel in position with special tool 11 0 300 (mandrel).

Fig 11: Securing Flywheel In Position Using Special Tool 11 0 300

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Secure flywheel with special tool (1) 11 9 260 and special tool (2) 11 9 266.

NOTE: Make sure that the special tool (1) completely engages in the flywheel teeth (see arrow)

Fig 12: Securing Flywheel Using Special Tool 11 9 260 And Special Tool 11 9 266

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Automatic transmission

Release flywheel bolts (1).

Release special tool (2).

Remove flywheel (3).

Fig 13: Identifying Flywheel With Mounting Bolts

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Manual transmission

IMPORTANT: Position crankshaft at top dead center.

Remove dual-mass flywheel.

Secure flywheel with special tool 11 9 260 (holder).

Remove VIBRATION DAMPER .

Release flywheel bolts with special tool 11 4 180 (socket WAF 46).

Fig 14: Removing Flywheel Bolts Using Special Tool 11 4 180

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Fig 15: Identifying Crankcase Bolts

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Release all crankcase bolts (1) along line (2).

Fig 16: Crankcase Bolts Tightening/Loosening Sequence

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Release crankcase bolts M10 in sequence 14 to 1.

Release crankcase lower section (1) from crankcase upper section (2) with suitable tool (3)

Remove crankcase lower section (1) upwards.

IMPORTANT: Do not rotate crankshaft without crankcase lower section (1) (risk of damage).

Fig 17: Removing Crankcase Lower Section From Upper Section Using Tool

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IMPORTANT: Timing chain is preloaded.

Do not raise crankshaft.

Carefully remove radial shaft seal (1).

Catch escaping engine oil with a cloth (2).

Fig 18: Removing Radial Shaft Seal

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Carefully remove radial shaft seal (1) towards front.

Catch escaping engine oil with a cloth (2).

Fig 19: Catching Escaping Engine Oil Using Cloth

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IMPORTANT: Protect crankcase against sealant residues with a cloth (1).

Fig 20: Protecting Crankcase Against Sealant Residues Using Cloth

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Remove sealing compound residues (1) with special tool 11 4 470 (cleaning kit).

Remove injector nozzles (2) for liquid sealing compound on left and right.

Installation note:

Replace injector nozzles (2).

Clean all threads with compressed air.

Fig 21: Identifying Injector Nozzle And Sealing Compound Residue

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Position crankcase lower section (1) on crankcase upper section.

Screw in all M10 crankcase bolts.

Joint all M10 crankcase bolts (1) 20 NM from inside outwards.

Fig 22: Positioning Crankcase Lower Section On Crankcase Upper Section

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Identify all M10 crankcase bolts with a colored marking (1) for checking.

Fig 23: Identifying M10 Crankcase Bolts With Colored Marking

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Fig 24: Crankcase Bolts Tightening/Loosening Sequence

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Secure crankcase bolts M10 in sequence 1 to 14 with special tool 00 9 120 (torque angle measuring dial).

Tightening torque:

Main bearing bolts (steel bolts 10.9)

M10 x 100

Replace bolts

Jointing torque: 20 Nm
Angle of rotation: 70 °

Fig 25: Identifying Crankcase Bolts

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Insert all crankcase bolts (1).

IMPORTANT: Observe different lengths and sizes of the bolts.

Tightening torque: see 2AZ, 3AZ, and 4AZ in 11 11 ENGINE BLOCK

Tighten screw (1) for oil pump triangular drive with special tool 11 8 640 (Torx socket).

NOTE: Replace screw.

Tightening torque: see 4AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Fig 26: Identifying Oil Pump Triangular Drive Mounting Screw

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Tighten screw plug on front of crankcase.

Tightening torque: see 11 41

Installation note:

Replace sealing ring.

Fig 27: Identifying Screw Plug On Front Of Crankcase

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Prepare radial shaft seal (1) on special tool 11 8 220.

Fig 28: Identifying Radial Shaft Seal On Special Tool 11 8 220

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Position radial shaft seal (1) with special tool 11 8 220 on crankshaft.

Fig 29: Positioning Radial Shaft Seal On Crankshaft Using Special Tool 11 8 220

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Brush radial shaft seal (1) over special tool 11 8 220.

Move radial shaft seal (1) parallel up against the crankcase.

Fig 30: Moving Radial Shaft Seal Parallel Up Against Crankcase

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Screw special tool 11 9 182 (synchronizing key) with screws (special tool 11 9 184) to crankshaft.

Fig 31: Mounting Special Tool 11 9 182 Over Crankshaft Using Screws

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Installation note:

Prepare special tool 11 9 181 (bush) for installation. Connect special tool 11 9 185 (ring) onto special tool 11 8 181.

Fig 32: Connecting Special Tool 11 9 185 To Special Tool 11 8 181

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Pull on radial shaft seal with special tool 11 9 181 (bush) and 11 9 185 (ring) in combination with special tool 11 9 183 (nut).

Fig 33: Pulling Radial Shaft Seal Using Special Tool 11 9 181/11 9 185/11 9 183

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Screw on radial shaft seal with special tool 11 9 183 (nut) to limit position.

Fig 34: Installing Radial Shaft Seal Using Special Tool 119 183

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Installation note:

Clean sealing surface (1) and degrease thoroughly in area of housing partition.

Apply a light coat of oil to running surface (2) of radial shaft seal.

NOTE: Graphic N42.

Fig 35: Identifying Sealing Surface And Running Surface For Crankshaft Radial Seal

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Push radial shaft seal (1) carefully in direction of arrow on the special tool 11 9 235 (spindle).

Fig 36: Pushing Radial Shaft Seal 11 9 235 Carefully On Special Tool

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IMPORTANT: Special tool 11 9 235 (spindle) can only be fastened with

2 opposite bolts.

Determine hole pattern on special tool.

Screw special tool 11 9 235 with special tool 11 9 234 (screw) on crankshaft.

Fig 37: Identifying Special Tools On Crankshaft

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Align groove (2) of radial shaft seal (1) centered to the housing partition (3.

IMPORTANT: After installation, the grooves must be filled with sealing compound.

Fig 38: Identifying Radial Shaft Seal Groove

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Draw in radial shaft seal with special tool 11 9 231 (bush) in conjunction with special tool 11 9 233 (nut) until flush.

Fig 39: Identifying Special Tools 119 231 And 11 9 233

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Drive both injector nozzles (1) on left and right with special tool 11 9 360 (mandrel) into crankcase up to stop.

Fig 40: Installing Nozzles Using Special Tool 11 9 360

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After fitting both sealing rings, check both sealing ducts for clearance.

Blow compressed air (1) at max. 6 bar into injector nozzle (2).

Compressed air must emerge at both sealing rings on left and right from the outlet bores.

IMPORTANT: If the compressed air does not flow out of all ducts. the crankcase must again be taken apart and cleaned.

Fig 41: Blowing Compressed Air Into Injector Nozzle

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Installation note:

Use primer and liquid gasket:

Loctite 171000 primer, BMW part number 83 19 7 515 683
Loctite 193140 liquid gasket, BMW part number 83 19 0 439 030

Prepare liquid sealing compound (1) in special tool 11 4 370 (pressing fixture).

Injector nozzles for injecting sealing compound are not required.

Fig 42: Identifying Liquid Sealing Compound, Injector Nozzles And Primer Bottle

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Slowly insert liquid sealing compound (1) with special tool 11 4 370 (pressing fixture) in direction of arrow.

Liquid sealing compound must emerge at radial shaft seals at front and rear.

Fig 43: Inserting Liquid Sealing Compound Using Special Tool 11 4 370

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Stop (seal off) escaping liquid sealing compound with primer (Loctite 171000 primer, BMW part number 83 19 7 515 683).

Fig 44: Stopping Escaping Liquid Sealing Compound With Primer

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Stop (seal off) escaping liquid sealing compound with primer (Loctite 171000 primer, BMW part number 83 19 7 515 683).

Fig 45: Stopping Escaping Liquid Sealing Compound With Primer

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Assemble engine.