Manual gearbox

IMPORTANT:

Position crankshaft at TDC.

Remove dual-mass flywheel.

Secure flywheel with special tool 11 9 260 .

Remove VIBRATION DAMPER .

Release flywheel bolts with special tool 11 4 180 .

Fig 1: Removing Flywheel Bolts Using Special Tool 11 4 180

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Fig 2: Identifying Crankshaft Bolt Mounting Area

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

Fig 3: 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 4: Removing Crankshaft (Lower Section And Upper Section) Using Tool

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IMPORTANT: Timing chain is pre-tensioned.
Do not raise crankshaft.

Carefully remove radial shaft seal (1).

Catch escaping engine oil with a cloth (2).

Fig 5: 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 6: Catching Escaping Engine Oil Using Cloth

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

Fig 7: Protecting Crankcase Against Sealant Residues Using Cloth

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Remove sealant residues (1) with special tool 11 4 470 .

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

Installation:

Replace injector nozzles (2).

Clean all threads with compressed air.

Fig 8: Identifying Injector Nozzle And Sealant 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) from inside outwards.

Tightening torque: 20 Nm

Fig 9: Screwing In All M10 Crankcase Bolts

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

Fig 10: Identify M10 Crankcase Bolts

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Fig 11: Crankcase Bolts Tightening/Loosening Sequence

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Secure crankcase bolts M10 in sequence 1 to 14 with special tool 00 9 120 .

Tightening torque: 11 11 1AZ

Fig 12: Identifying Crankcase Bolts

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Insert all crankcase bolts (1).

IMPORTANT: Observe different lengths and sizes of the bolts.

Tightening torque: 11 11 2AZ / 3AZ / 4AZ

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

NOTE: Replace screw.

Tightening torque: 11 41 4AZ .

Fig 13: Identifying Oil Pump Triangular Drive Mounting Screw

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Tighten screw plug on front of crankcase.

Tightening torque: 11 11 8AZ

Installation:

Replace sealing ring.

Fig 14: Identifying Screw Plug On Crankcase

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

Fig 15: 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 the crankshaft.

Fig 16: Positioning Radial Shaft Seal Using Special Tool 11 8 220 On Crankshaft

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

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

Fig 17: Moving Radial Shaft Seal Parallel Up Against Crankcase

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

Fig 18: Screwing Special Tool 11 9 182 With Screws (Special Tool 11 9 184) To Crankshaft

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Installation:

Prepare special tool 11 9 181 for installation. Connect special tool 11 9 185 onto special tool 11 8 181.

Fig 19: Connecting Special Tool 11 9 185 Onto Special Tool 11 8 181

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Pull on radial shaft seal with special tool 11 9 181 and 11 9 185 in combination with special tool 11 9 183.

Fig 20: 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 to limit position.

Fig 21: Screwing On Radial Shaft Seal Using Special Tool 11 9 183

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Installation:

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

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

NOTE: Graphic N42.

Fig 22: Identifying Sealing Surface And Running Surface For Crankshaft Radial Seal

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

Fig 23: Pushing Radial Shaft Seal (11 9 235) On Special Tool

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IMPORTANT: 11 9 235Special tool can only be fastened with
2 opposite bolts.
Determine hole pattern on special tool.

Fig 24: Mounting Special Tool 11 9 235 With Special Tool 11 9 234 On Crankshaft

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Screw special tool 11 9 235 with special tool 11 9 234 on crankshaft.

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 25: Identifying Radial Shaft Seal, Housing Partition And Groove

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Draw in radial seal with special tool 11 9 231 in conjunction with special tool 11 9 233 until flush.

Fig 26: Inserting Radial Seal With Special Tool 11 9 231 And 11 9 233

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

Fig 27: Inserting 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 28: Blowing Compressed Air Into Injector Nozzle

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Installation:

Use PRIMER 1.3 AND LIQUID SEAL 1.4.

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

Injector nozzles for injecting sealing compound are not required.

Fig 29: Identifying Injector With Primer Bottle

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

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

Fig 30: Inserting Liquid Sealing Compound Using Special Tool 11 4 370

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 31: Coating Surface Of Sealing Compound In Both Grooves Using Loctite Primer

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 32: Sealing Escaping Liquid Gasket With Primer

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Assemble engine.