Assembling Engine

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information 

Always replace gaskets and O-rings.

• Grease all gaskets (except for the cooling system) with Kluber Syntheso Glep (Part No. 000.043.204.68). 

Information 

• The tightening torques for the engine are listed in the following documents and must be used in accordance with these specifications. 

Technical values and tightening torques: 

Repair group 1: → 1X00IN TECHNICAL VALUES .

Repair group 2: → 2X00IN TECHNICAL VALUES .

Overview of bearing shell allocation: 

Fig 1: Identifying Crankshaft Shell

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1. Main bearing shells - red, yellow, blue
2. Partial-groove bearing shells - red, yellow, blue
3. Thrust washers
4. Supporting mount shells - red, yellow, blue

1. Fit crankcase half 4-6 on the engine assembly support.
   1. 1.1. Use mounting parts 9590  to secure to the engine adapter 9771  .

   → 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ENGINE ASSEMBLY SUPPORT .

   Information 

   • The bearing shells must be allocated according to specifications. 
   • Observe difference between partial-groove bearings and smooth bearings. 
   • Coat bearing shells with new engine oil. 
2. Fit new bearing shells on crankcase half 4-6. The following markings ensure correct allocation.
   1. 2.1. Crankcase half 4-6:  Markings are on the crankshaft. The upper series of letters -1-  is for the crankcase. Allocation starts at the supporting mount -SL-  on the belt side and is read from left to right. The supporting mount does not have a number, while the main bearings are numbered -HL: 1 to 7-  (number 7 is at the flywheel side).
      1. Series of letters at the top, supporting mount shells and main bearing shells
      2. Series of letters on connecting-rod bearing shells
      1. SL  - Supporting mount
      2. HL  - Main bearing
      3. PL  - Connecting-rod bearing
      4. R  - Bearing shell, Red
      5. G  - Bearing shell, Yellow
      6. B  - Bearing shell, Blue
      Fig 2: Identifying Crankshaft Bearing Shell Mark

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3. Fit new bearing shells on crankcase half 1-3.
   1. 3.1. Crankcase 1-3:  Markings -1-  on crankcase half. The series of letters is read from left to right. Allocation starts at the flywheel side and ends at the supporting mount on the belt side.
      1. G  - Bearing shell, Yellow
      2. R  - Bearing shell, Red
      3. B  - Bearing shell, Blue
      Fig 3: Identifying Crankcase Marking

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   2. 3.2. There are also different types of bearing shells (see bearing shell allocationFig 1).
      1. Partial-groove bearing shell (cylinders 2, 4 and 6)
      2. Smooth bearing shell
      Fig 4: Identifying Crankcase Bearing Shells

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   3. 3.3. Fit and grease new O-ring on the crankcase sealing face.
4. Insert two thrust washers -1-  on main bearing 4. Oil grooves must always be facing outwards.
   Fig 5: Locating Thrust Washer Position

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   Information 

   • Check guide and tensioning rails for visible and obvious signs of wear before installation and replace if damaged. 
   • The tensioning rails on cylinder bank 1-3 and 4-6 are identical. 
   • The guide rails on cylinder bank 1-3 and 4-6 are identical. 
   • The slots in the cylinder head must be positioned during installation. 
5. Install tensioning rail for oil-pump drive chain in crankcase 4-6.
   1. Rail
   2. Tensioning spring
   Fig 6: Identifying Oil-Pump Timing Chain Tensioning Rail

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   1. 5.1. Fit tensioning rail -1-  for oil pump chain using a short bearing pin.
      Fig 7: Identifying Oil-Pump Drive Tensioning Rail

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6. Fit guide rail for cylinder bank 4-6 and secure in the crankcase with a short bearing pin -2-  .
   1. Oil pump supply valve on vacuum pump
   2. Bearing pin for guide rail
   3. Bearing pins for tensioning rail
   4. Bearing pin for tensioning rail for oil-pump drive chain
   Fig 8: Identifying Cylinder Bank Bearing Pins (4-6)

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   1. 6.1. Place spring -2-  on tensioning rail -1-  for oil-pump drive chain into the cut-out in the guide rail -3-  .
      Fig 9: Identifying Tensioning Spring Position

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7. Insert crankshaft with timing chains -2 and 3-  .
   1. 7.1. Engage oil pump gear -1-  in the drive chain.
      Fig 10: Identifying Crankshaft

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8. Fix crankshaft in place using special tool holding bridge 9779 -1-  .
   1. 8.1. Fit and tighten fastening screws -2-  hand-tight.
      Fig 11: Placing Crankshaft

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9. Install pistons on cylinder bank 4-6 and connecting rods 1-3.

   → 131020 REMOVING AND INSTALLING PISTONS AND HANDLING TOOLS .

10. Replace through bolts.

    Once the sealing washers are approved as spare parts in the Spare Parts Catalogue, the sealing washers can be replaced and the screws can be re-used! To do this, proceed as follows: 

    1. 10.1. Fit through bolts -1-  with new sealing washers.
    2. 10.2. Protective sleeve 9786 -2-  must be pulled over the screw thread. Guide sealing washer -3-  over the protective sleeve for the screw head and remove protective sleeve.
       1. Through bolt
       2. Protective sleeve 9786
       3. Sealing washer (not yet available as a spare part)
       Fig 12: Identifying Sealing Washer And Protective Sleeve

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    Information 

    • The sealing faces of the crankcase halves must be completely free of oil, grease and burrs before applying sealant. 
    • Apply a bead of sealant with a diameter of no more than 1 mm. Always apply sealant to the required area only. 
    • Join the crankcase halves within max. 5 minutes of applying the bead of sealant. 
11. Apply sealant to crankcase half 4-6. Observe processing instructions.
    1. 11.1. Use Dobotech sealing compound (Part No. 000.043.207.31).
    2. 11.2. Carefully apply a continuous bead of sealant -arrow 1-  with a diameter of 1 mm. Follow sealant contour as shown in Fig 13.
    3. 11.3. Remove residual silicone in the crankshaft flange area following installation -arrow 2-  .
       Fig 13: Locating Crankcase Sealant Applying Area

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12. Fit rubber sleeves on connecting rods 1-3 (assembly aid 9795  ) and position vertically.
    1. 12.1. The restraining straps P221  can be used if necessary. Only two connecting rods can be fixed in place in this case. The third connecting rod must be held when positioning the crankcase half.

    Information 

    Get another person to help you join crankcase halves 1-3. 

13. With the help of a second person, place crankcase half 1-3 on crankcase half 4-6.
14. Fit through bolts and tighten according to the specified tightening torque and sequence.

    → 1X00IN TECHNICAL VALUES

    Fig 14: Crankcase Bolts Tightening Sequence

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    1. 1-14  - External Torx screw with sealing washer
15. Fit external Torx screws for the outer cross bolt connection and tighten according to the specified tightening sequence.

    → 1X00IN TECHNICAL VALUES

    Fig 15: Crankcase Bolts Tightening Sequence

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16. Screw in and tighten two mounting parts 9590  for bolting crankcase half 1-3 to the engine support.
17. Install pistons for cylinder bank 1-3.

    → 131020 REMOVING AND INSTALLING PISTONS .

18. Turn the crankshaft clockwise a number of times at the vibration damper using turning device 9773  in order to check for smooth operation and correct function.
    1. 18.1. Then, turn the crankshaft so that none of the pistons are at top dead center (TDC).
19. Fit crankshaft sealing rings at the flywheel and drive side.

    → 137455 REPLACING CRANKSHAFT SEALING RING (ON BELT SIDE) .

    .

20. Fit tensioning rail for cylinder bank 4-6 using a long bearing pin -3-  .
    Fig 16: Identifying Cylinder Bank Bearing Pins (4-6)

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    1. 20.1. Fit tensioning rail for cylinder bank 1-3.
    2. 20.2. Secure guide rail for cylinder bank 1-3 in the crankcase with long bearing pins -1-  .
       Fig 17: Identifying Cylinder Bank Bearing Pins (1-3)

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    3. 20.3. Tighten bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
21. Fit the oil guide (oil plate) -1-  using external Torx screws -2-  .
    Fig 18: Identifying Crankcase Oil Guide

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22. Install oil pump.

    → 172019 REMOVING AND INSTALLING OIL PUMP .

23. Install coolant pipe -1-  for the coolant pump.
    1. 23.1. Fit and tighten external Torx screws -2-  .
       Fig 19: Identifying Coolant Pipe

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24. Insert displacement bodies -1-  on cylinder bank 1-3.
    Fig 20: Identifying Cylinder Bank Marking Pistons (1-3)

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    Information 

    • Always guide timing chains with your hand when turning the crankshaft. 
25. Fit cylinder head 1-3 and 4-6.

    → 157019 REMOVING AND INSTALLING CYLINDER HEAD .

26. Pull timing chain 1-3 out of the chain slot and fit oil supply valve
    1. -1-  for the vacuum pump on the cylinder head with a new O-ring
    2. -2-  . Engage timing chain at the valve.
    Fig 21: Identifying Oil Supply Valve

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27. Hold tensioning rail -1-  for cylinders 1-3 using a pair of flat-nosed pliers -3-  and screw in bearing pin -4-  .
    Fig 22: Installing Tensioning Rail And Guide Rail

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    1. 27.1. Secure guide rail for cylinders 4-6 in the cylinder head with a short bearing pin.
    2. 27.2. Tighten both bearing pins to the specified torque: 10 Nm (7.5 ftlb.)  .
28. Check installation position of tensioning rail for oil-pump drive chain and guide rail again.
    1. Tensioning spring for tensioning rail
    2. Guide rail
    Fig 23: Identifying Oil-Pump Drive Chain And Guide Rail Tensioning Rail

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29. Install oil pan.

    → Installing Oil Pan

30. Install hydraulic valves for camshaft control with new O-rings.
    1. 30.1. Tighten external Torx screws.
31. Install camshafts.

    → Installing Camshafts And Setting Timing .

32. Install cylinder head cover.

    → Installing Cylinder Head Cover .

33. Fit cover for positive crankcase ventilation.
    1. 33.1. Fit cover for cylinder bank 1-3 -1-  with new gaskets -2 and 3-  and secure with external Torx screws -4-  .
       Fig 24: Identifying Positive Crankcase Ventilation Cover (1-3)

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    2. 33.2. Fit cover for cylinder bank 4-6 -1-  with a new O-ring -2-  and secure with external Torx screws -3-  .
       Fig 25: Identifying Positive Crankcase Ventilation Cover (4-6)

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34. Fit spark plugs.

    → Installing Spark Plugs .

35. Install ignition coils.

    → 282020 REMOVING AND INSTALLING IGNITION COILS .