Assembling Crankshaft

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165  on the engine assembly support.

1. Clamp crankshaft in a vice using the retainer plate P209a  .
2. Sputtered bearing shells are used on the connecting rods. These have two locking lugs to differentiate them and to avoid confusion.
   Fig 1: Locating Sputtered Bearing Shell On Connecting Rod

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3. Conventional bearing shells with one retaining lug are fitted on the connecting-rod caps.
   Fig 2: Locating Bearing Shell On Connecting-Rod Cap

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   Information 

   Fit the connecting rods in such a way that the matching numbers are all facing the observer.

4. Lubricate the con-rod journals with grease (Optimol Optipit) and fit the connecting rods on the crankshaft. → Matching number on con-rod assembly 
   Fig 3: Greasing Con-Rod Journals

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   Fig 4: Locating Matching Number On Con-Rod Assembly

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5. Tighten connecting rod nuts to the prescribed tightening torque.
6. After the tightening procedure, check that the connecting rod bolt is not twisted. → Initial tightening: 30 Nm (22 ftlb.)  ; → Torque angle: 90°+/-2° 
   Fig 5: Checking Connecting Rod Bolt

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7. Insert and align new Woodruff key for timing gear.

   Information 

   • The collar of the timing gear must point to bearing 7. 
8. Heat timing gear to approx. 150 - 200 °C on a heating plate. Remove timing gear from the heat source with a piston restraining strap and quickly fit or slide it into place on the crankshaft journal.
   Fig 6: Fitting Timing Gear

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9. Heat the intermediate ring in the same way and slide it on as far as it will go.

   Information 

   • The circlip must be inserted without play. 

   The following parts are available for fitting the circlip: 

   Part No.	Thickness (mm)	Identifying feature
   901.102.148.00	2.4	blank
   901.102.148.01	2.3	tempered blue(1)
   901.102.148.02	2.2	tempered yellow/brown
   901.102.148.03	2.1	black, gun-metal finish
   (1) most frequently used circlip for first assembly.

10. Select the required circlip by performing an insertion test.
11. The opening on the circlip should lie opposite the Woodruff key groove → Circlip on crankshaft  .
    Fig 7: Locating Circlip On Crankshaft

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12. Tap the circlip into the retaining groove with a blunt chisel.
    Fig 8: Tapping Circlip

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