Installing Crankshaft

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

• O-rings are also inserted on two through bolts on the thrust block mount (thrust blocks 2 and 4). 
• These through bolts must be fitted before joining the crankcase halves. 

Information 

Always replace gaskets and O-rings.

1. Secure the engine support holder P201  and engine support 9667  to crankcase half 4-6.
2. Check the matching number of the crankcase halves. The number is located on the top of the head lug -arrow-  .
   Fig 1: Locating Mark On Crankcase Halves

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3. Allocation of the crankshaft gearwheel and intermediate shaft to the crankcase.
   1. 3.1. The tolerance group number is imprinted on the crankcase -arrow-  and must match the number on the intermediate-shaft gearwheel and the crankshaft gearwheel.
      Fig 2: Locating Tolerance Group Number On Crankcase

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   2. 3.2. Marking on intermediate-shaft gearwheel -arrow-  :
      Fig 3: Locating Matching Number On Intermediate-Shaft Gearwheel

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   3. 3.3. Marking on crankshaft gearwheel -arrow-  :
      Fig 4: Locating Matching Number On Crankshaft Gearwheel

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4. 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.
   Fig 5: Identifying Intermediate Shaft Bearing Shells (4-6)

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6. Oil bearing shells for intermediate shaft, insert intermediate shaft and check visually for true running.
   Fig 6: Checking Intermediate Shaft Visually For True Running

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7. Insert new crankshaft bearing shells into the crankcase. Oil the bearings.
8. Check that dowel sleeves are seated correctly -arrows-  .
   Fig 7: Locating Dowel Sleeves On Crankcase

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9. Carefully insert crankshaft (without bearing 8) into crankcase half 4-6.
   1. 9.1. Get another person to help if necessary.

   Information 

   • If the wear dimension of the intermediate shaft/drive wheel pairing is reached, replace it. 
10. Check backlash on intermediate shaft → Checking backlash on intermediate shaft. The sealing face must not be damaged during this procedure.
    1. 10.1. To do this, secure universal dial gauge bracket VW 387  to the crankcase joint.
    2. 10.2. Align the dial gauge on a tooth profile and measure the amount of play.
    3. 10.3. Then turn the intermediate shaft by 180° and repeat the measurement.
       Fig 8: Checking Backlash On Intermediate Shaft

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    Designation	New measured value in mm	Wear dimension
    Backlash	0.035 - 0.084	0.10 mm

11. Remove intermediate shaft again.
12. Get another person to lift the crankshaft slightly and slide bearing no. 8  onto the crankshaft journal.
    1. 12.1. Slowly lower the crankshaft and insert crankshaft bearing no. 8 in the dowel pin -arrow-  .
       Fig 9: Fitting Crankshaft Bearing No. 8

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13. Check installation position. If the position is correct, the center of the bearing notch should level with the sealing face → Installation position of crankshaft  .
    1. 13.1. Clean the crankshaft flange to remove grease.
       Fig 10: Identifying Crankshaft Installation Position

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14. Fit shaft sealing rings on the crankshaft flange.

    Observe fitting instructions.

    → 135919 REMOVING AND INSTALLING CRANKSHAFT SEALING RING - GT3 (FLYWHEEL SIDE) .

    → 137419 REMOVING AND INSTALLING CRANKSHAFT SEALING RING - PULLEY SIDE 

    Fig 11: Identifying Crankshaft Sealing Ring (Flywheel Side)

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    Information 

    For all lubrication points, use Kluber Syntheso Glep (Part No. 000.043.204.68).

15. 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 -arrow-  .
    Fig 12: Locating Sealing Ring On Oil Pump Mount

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16. Insert oil pump with connecting shaft and intermediate shaft with both timing chains into the crankcase half.

    Information 

    • Always replace lock nuts. 
17. Fit and tighten three new M8 collar nuts -arrows-  .

    → Tightening torque: 23 Nm (17 ftlb.) 

    Fig 13: Locating Collar Nuts On Oil Pump

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18. Check connecting shaft. The connecting shaft must move freely in axial direction -arrows-  .
    1. 18.1. Loosen the oil pump with intermediate shaft again if necessary and shift the connecting shaft.
       Fig 14: Checking Connecting Shaft Between Oil Pump And Intermediate Shaft

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19. Insert inner through bolts.
    1. 19.1. On thrust blocks -2 and 4-  , also fit O-rings -arrows-  .
       Fig 15: Locating Through Bolts On Thrust Block (2 And 4)

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    Information 

    • Do not oil sealing rings until shortly before fitting. 
    • Do not store oiled sealing rings. 
20. Prepare four through bolts.
    1. 20.1. Slide sealing washers onto the through bolts.
    2. 20.2. Guide lightly oiled O-rings with conical sleeve from special tool assembly sleeve 9511  over the threaded area and push them onto the conical section towards the head of the bolt → Preparing through bolts for assembly  .
       Fig 16: Identifying Through Bolts (Assembly)

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21. Check the various diameters on the assembly sleeve 9511 -A and B-  .
    Fig 17: Identifying Assembly Sleeve 9511

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22. Insert the prepared through bolts as far as they will go into the right crankcase half from below and hold at this position.
    1. 22.1. Be careful with the O-ring -arrow-  .
       Fig 18: Locating Through Bolts

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23. Fit second O-ring.
    1. 23.1. Fit conical sleeve on the end of the thread.
    2. 23.2. Slide dry O-ring over the conical sleeve -arrow-  .
       Fig 19: Locating Conical Sleeve For Fitting Through Bolts

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    3. 23.3. Remove conical sleeve and push the O-ring with the cylinder sleeve as far as the chamfer in the thrust block -arrow-  .
       Fig 20: Pushing O-Ring With Cylinder Sleeve

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    4. 23.4. Assembly sleeve 9511  must now be removed.
24. Lift connecting rod of cylinder 4, 5 and 6 using special tool restraining straps P221  .
    1. 24.1. Secure the timing chain with a restraining strap.
       Fig 21: Placing Connecting Rods In Vertical Position

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25. Grease two new sealing rings on the oil pump and the new sealing ring on the crankcase half with Kluber Syntheso Glep and insert them.
    Fig 22: Locating Sealing Rings On Oil Pump And Crankcase Half

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26. Prepare crankcase halves of cylinder bank 1-3.
    1. 26.1. Insert the bearing shells of the crankshaft and intermediate shaft. Be careful with the dowel pin -arrow-  .
       Fig 23: Locating Dowel Pin

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27. Remove any grease from the sealing face of the crankcase halves using acetone or solvent naphtha.
    1. 27.1. Apply a uniform bead of sealant approx. 1.5 mm wide to the sealing face of crankcase half 1-3.
    2. 27.2. Only use Drei Bond 2210 sealant. 
       Fig 24: Locating Sealant Applying Area To Crankcase Half

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28. Check the relief groove close to main bearing no. 7 -arrow-  for foreign objects (e.g. silicone residue) and clean it if necessary.
    Fig 25: Locating Relief Groove On Main Bearing 7

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    Information 

    • Cover the chain slot briefly when fitting so that parts do not fall into the crankcase. 
29. Carefully insert the crankcase half over the pre-fitted through bolts (thrust block 2 to 5).
    1. 29.1. A second person must hold up the timing chain through the chain space at the same time.
30. Restraining straps P221  must now be removed.
31. Join the crankcase halves and secure them with six new lock nuts with washers.
    1. 31.1. Distribute the lock nuts evenly around the joint and tighten by hand.
       Fig 26: Locating Lock Nuts On Cross Bolt Connection

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32. Insert the prepared through bolts for crankcase half 4-6 and hold them securely.
33. Slide the conical sleeve of special tool assembly sleeve 9511  with an oiled O-ring to the end of the thread.
    Fig 27: Inserting Conical Sleeve With Oil Sealing Ring

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34. Slide the O-ring carefully over the conical sleeve with the -A side-  of the cylinder sleeve (thin wall).
    Fig 28: Identifying Special Tool Assembly Sleeve 9511

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    1. 34.1. Using the cylinder sleeve -arrow-  .
       Fig 29: Fitting O-Ring For Through Bolt

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35. 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.
36. Fit dry sealing washers and press downwards slightly with the B side  of the cylinder sleeve.
37. Screw on outer multiple-tooth nuts (thread oiled) by hand.
38. Proceed in the same way with both studs on crankcase half 4-6 (bearing 1 area) on the flywheel side.
39. Screw M10 multiple-tooth nut onto the stud (thread oiled) in the chain box -arrow-  .
    Fig 30: Locating Fastening Nuts On Chain Box

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    Information 

    • When tightening the through bolts without using retaining device 9662, it is imperative that a second person counters at the bolts. 
    • The O-ring will be damaged when the through bolts are turned. 
    • Counter using a multiple-tooth socket (a/f 14 mm). 
40. Retaining device 9662  must be fitted on the corresponding through bolt and can then be positioned using an aluminum sleeve from the set of retaining nuts P140  . → Retaining device 9662 
    Fig 31: Identifying Retaining Device 9662

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41. Bolt the crankcase halves.
    1. 41.1. Tighten through bolts on side 1-3 according to the specified tightening sequence -1-11-  and specifications (see table  below).
       Fig 32: Through Bolts Tightening Sequence

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    2. 41.2. Tighten M10 multiple-tooth nut -12-  on the stud in the chain box on side 1-3 according to specifications (see table ).
       Fig 33: Locating Multiple-Tooth Nut M10 In Chain Box

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    3. 41.3. Tighten through bolts -13 and 14-  on the flywheel side (side 4-6) according to specifications (see table ).
       Fig 34: Locating Through Bolts On Flywheel Side

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    4. 41.4. Tighten new self-locking hexagon nut -15-  and washer.

       → Tightening torque: 25 Nm (19 ftlb.) 

       Fig 35: Locating Lock Nut On Chain Box

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       CRANKCASE BOLTS TIGHTENING TORQUES SPECIFICATIONS
       
       

       Sequence	Designation	Bolts	Value
       Step 1	Initial tightening	Through bolts, long, No. 1-11 (side 1-3)	15 Nm (11 ftlb.)
       Step 2	Initial tightening	Multiple-tooth nut on chain box, side 1-3	15 Nm (11 ftlb.)
       Step 3	Initial tightening	Through bolts, short (side 4-6)	15 Nm (11 ftlb.)
       Step 4	Final tightening	Through bolts, long, No. 1-11 (side 1-3)	15 Nm (11 ftlb.) and 210° torque angle
       Step 5	Final tightening	Multiple-tooth nut on chain box, side 1-3	15 Nm (11 ftlb.) and 110° torque angle
       Step 6	Final tightening	Through bolts, short (side 4-6)	15 Nm (11 ftlb.) and 110° torque angle
       Step 7	Final tightening	Cross bolt connection	25 Nm (19 ftlb.)

42. Fit and tighten 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.

43. Fit aluminum pulley using a new fastening screw (M14 x 1.5) and a new friction washer.

    → 137619 REMOVING AND INSTALLING PULLEY  .

    When tightening the pulley, a second person must counter with the retaining tool. 

    1. 43.1. Tighten the fastening screw.

       → Tightening torque: 170 Nm (126 ftlb.) 

44. Fit the flywheel.

    → 136019 REMOVING AND INSTALLING FLYWHEEL .

    → 136019 REMOVING AND INSTALLING SINGLE-MASS FLYWHEEL .