Removing And Installing Crankcase And Bearing Housing With Crankshaft: Removal

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Detach thrust plate or flywheel. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.

Fig 1: Installing Toothed Segment (Special Tool 9538/1)
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Detach thrust plate and remove with drive plate. Detach and remove the flywheel.
Clamp crankcase. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.

Fig 2: Installing Special Tool 9589 To Crankcase Half
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Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6).

Fig 3: Locating Primary Chain Tensioner
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Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool (socket wrench insert 9594); to do this, hold with holding device (special tool 9593).

Fig 4: Loosening Belt Pulley
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Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the locknut using the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin.

Fig 5: Installing Special Tool 9110 On Intermediate Shaft Flange
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Remove coolant guide housing.

Fig 6: Removing Coolant Guide Housing
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Undo fastening screws between crankcase half of cylinder bank 1-3 and bearing housing.

Fig 7: Locating Fastening Screws Between Crankcase Half Of Cylinder Bank 1-3
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Fig 8: Removing Crankcase Screws
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Undo fastening screw between crankcase half of cylinder bank 4-6 and bearing housing.

Fig 9: Locating Fastening Screws Between Crankcase Half Of Cylinder Bank 4-6
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Fig 10: Removing Fastening Screws Between Crankcase Half Of Cylinder Bank 4-6
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Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer. Remove air-oil separator. See REMOVING AND INSTALLING AIR/OIL SEPARATOR .
Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 25 ea.) joining the crankcase halves.
Carefully lift the crankcase half up and off. Do not tilt - this might damage the pistons.

Fig 11: Lifting Crankcase
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Mark pistons. Lever off front piston pin circlip. Push out piston pin.

Fig 12: Pushing Out Piston Pin
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Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 20 hexagon-head bolts.

Fig 13: Installing Special Tool 9607 On The Bearing Housing
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