Disassembling and assembling bearing housing with crankshaft: Tools
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SPECIAL TOOL DESIGNATION
| Item | Designation | Special tool | Explanation |
|---|---|---|---|
| Assembly fixture for bearing housing | 9607 | Fasten bearing housing with two M10 x 30 hexagon-head bolts. |
CAUTION:
Danger to engine if connecting-rod bearing cap and connecting rod are mixed up!
- The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.
Recommendation: After disassembly, immediately re-join the connecting-rod bearing cap and connecting rod or mark them on the sides with an electric scribing tool (e.g. with the cylinder designation). Never mark these parts with sharp objects such as prick punches or number embossing tools.
CRANKSHAFT WITH BEARING HOUSING - REMOVAL INSTALLATION
| No. | Designation | Qty. | Removal | Installation |
|---|---|---|---|---|
| 1 | Connecting-rod bolt | 6 | Lightly oil thread and bearing surface | |
| 2 | Connecting-rod bearing cap, cyl. 4 | 1 | ||
| 3 | Connecting rod, cyl. 4 | 1 | Immediately join with the connecting-rod bearing cap after removal | |
| 4 | Connecting-rod bearing cap, cyl. 5 | 1 | ||
| 5 | Connecting rod, cyl. 5 | 1 | Immediately join with the connecting-rod bearing cap after removal | |
| 6 | Connecting-rod bearing cap, cyl. 6 | 1 | ||
| 7 | Connecting rod, cyl. 6 | 1 | Immediately join with the connecting-rod bearing cap after removal | |
| 8 | Connecting-rod bearing shell half | 6 | Replace | |
| 9 | Thrust-bearing screw M9 x 127 | 14 | Lightly oil bearing surface and thread | |
| 10 | Bearing housing half, cylinder bank 1 - 3 | 1 | ||
| 11 | Crankshaft bearing shell half | 7 | Replace; insert in correct position, locating stud faces towards dowel-sleeve side | |
| 12 | Oil spray jets for piston cooling in bearing housing half, cylinder bank 1 - 3 | 3 | Press out from rear side of bearing housing half using a plastic mandrel | Press in with plastic mandrel (4 mm) |
| 13 | Cylindrical pin A4.0 x 10 | 1 | Check for bending | |
| 14 | Roll pin 6.0 x 16 | 1 | ||
| 15 | 1 | Crankshaft | Check axial play. Never process bearing pins e.g. by sanding | |
| 16 | Thrust plate | 2 | Replace, insert in correct position into bearing-housing half (cyl. 4 - 6), oil groove faces the belt pulley, oil groove of opposite thrust plate faces the flywheel, insert thrust plates with grease | |
| 17 | Crankshaft bearing shell half | 7 | Insert in correct position, locating stud or anti-turn lock towards dowel-sleeve side | |
| 18 | Oil spray jets for piston cooling in bearing housing half, cylinder bank 4 - 6 | 3 | Press in with plastic mandrel (4 mm) | |
| 19 | Dowel sleeve in bearing housing half cylinder bank 4 - 6 | 3 | Check that it is present and seated properly | |
| 20 | Pin for tensioning rail | 1 | Press into bearing housing half (cyl. 4 - 6) | |
| 21 | Bearing housing half, cylinder bank 4 - 6 | 1 | Do not damage sealing surfaces, fit on assembly fixture (special tool 9607) and fasten with M10 x 30 hexagon-head bolts |
WARNING:
Bearing housings without connecting-rod bearing twist locks should not be installed.
BEARING HOUSING AND CRANKSHAFT REMOVAL/INSTALLATION PROCEDURE
| No. | Procedure | Instructions |
|---|---|---|
| 1 | Checking that sealing balls are present | Check that sealing balls (6 ea.) are present and correctly caulked. Rework if necessary. |
| 2 | Fitting dowel sleeves | Push dowel sleeves (3 ea.) into the main thrust bearings 7, 4 and 1 of the bearing-housing half, cyl. 4 - 6, as far as the stop. |
| 3 | Fitting oil spray jets for piston cooling | Press oil spray jets into the receiving bore with a plastic mandrel (4 mm). |
| 4 | Inserting crankshaft bearing shells | Lay crankshaft bearing shells in the main thrust bearings. Fit the locating stud or the locating stud of the twist lock on the dowel-sleeve side. Lightly oil sliding surfaces. |
| 5 | Inserting thrust plates | Insert the thrust plates in the recess of main thrust bearing 4 of the bearing-housing half of cyl. 4 - 6. The oil pockets must face pulley or flywheel side. |
| 6 | Checking thrust plates | After inserting the crankshaft, check the two thrust plates at main thrust bearing 4 for correct seating. |
| 7 | Tightening thrust-bearing screws | Oil thread and contact surface. |
| Tightening specification | 1. Initial tightening 25 Nm (19 ftlb.) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a colour line. | |
| 2. Final tightening 1 x 90° turn Observe tightening sequence: see Assembly instructions. | ||
| 8 | Checking axial play of crankshaft | Screw gauge with gauge holder VW 387 to bearing housing and place against crankshaft flange. Press crankshaft by hand against the gauge and set gauge to zero. Press crankshaft away from gauge. Read off value: New installation 0.05 to 0.24 mm Wear limit 0.28 mm |
| 9 | Inserting connecting-rod bearing shells | Insert connecting-rod bearing shells into connecting rod. Lubricate sliding surface liberally with grease, e.g. Optimol Optipit (00004320417). |
| Note Grease to facilitate assembly during subsequent piston pin installation of cylinder bank 4 - 6. | ||
| 10 | Completing connecting rod | Join connecting rod and connecting-rod bearing cap. The recesses of the connecting-rod bearing twist lock must face each other. |
| Tightening specification | Oil thread and contact surface. | |
| 1. Initial tightening 20 Nm (15 ftlb.) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a colour line. 2. Final tightening 1 x 90° turn |