Pre-Assembly Of Crankcase Halves

NOTE: Dirt and contamination

Risk of damage to units or components
→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

Information

Overview of bearing shell allocation:

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Bearing shell allocation

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

Fit crankcase half for cylinder bank 2 on the engine assembly support using > 9590 - mounting parts and > 9771 - engine adapter .

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

Information

Crankcase half, cylinders 4 to 6:

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Marking for bearing shell allocation on crankshaft

1	Series of letters at the top, supporting mount shells and main bearing shells
2	Series of letters on connecting-rod bearing shells
SL	Supporting mount
HL	Main bearing
PL	Connecting-rod bearing
R	Bearing shell, Red
G	Bearing shell, Yellow
B	Bearing shell, Blue

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.
Read off from left to right.
The supporting mount -SL- does not have a number, while the main bearings -HL- are numbered -1 to 7- (number 7 is at the flywheel side).

Information

Bearing shells must be allocated according to specifications.
Observe differentiation between partial-groove bearings and smooth bearings.
Coat new bearing shells with new engine oil.

Information

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Bearing shells fitted on crankcase

1	Partial-groove bearing shell (cylinders 2, 4 and 6)
2	Smooth bearing shell

There are different types of bearing shells (see bearing shell allocation)

Fit new bearing shells on crankcase half 4-6.

Grease two thrust washers -1- with Optimol Optipit (Part No. 000.043.204.17) and fit them on main bearing 4.

Oil guide grooves must be on the outside!

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Position of grooves on thrust washer

Information

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Marking on crankcase half for cylinders 1 to 3

G	Bearing shell, Yellow
R	Bearing shell, Red
B	Bearing shell, Blue

Marking -1- on crankcase half for cylinders 1 to 3. Allocation starts at the flywheel side. Read off series of letters from left to right.

Information

Bearing shells must be allocated according to specifications.
Observe differentiation between partial-groove bearings and smooth bearings.
Coat new bearing shells with new engine oil.

Information

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Bearing shells fitted on crankcase

1	Partial-groove bearing shell (cylinders 2, 4 and 6)
2	Smooth bearing shell

There are different types of bearing shells (see bearing shell allocation)

Fit new bearing shells on the crankcase half of cylinder bank 1.

Install tensioning rail -1- with a long bearing pin -2- in the crankcase half.

5.1 Fit spacer sleeve.

5.2 Insert tensioning rail -1- in crankcase half 4-6.

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Tensioning rail for oil pump drive in crankcase

5.3 Secure tensioning rail in the crankcase using a long bearing pin -2- .

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Bearing pin

Insert guide rail for crankcase half, cylinder bank 2 and fix in place in the crankcase using a long bearing pin -1- .

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Bearing pin
Fit tensioning spring -2- on tensioning rail -1- into the cut-out in the guide rail -3- .

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Position of tensioning spring in guide rail
Tighten bearing pins on guide and tensioning rails.
> Tightening torque 10 N.m (7.5 ft lb.)
Insert crankshaft with timing chains -2 and 3- and engage oil pump gear -1- in the drive chain.
1. 9.1 Guide timing chains with your hand when turning the crankshaft so that they do not get stuck in the crankcase.
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Crankshaft in crankcase half 4-6
Check installation position of tensioning spring on tensioning rail -1- for the oil-pump drive chain and guide rail -2- again.

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Tensioning rail for oil-pump drive chain and guide rail
Insert crankshaft with > P90028 - retaining bridge-1- and screw in screws -2- as far as they will go by hand.

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Holding bridge P90028 for crankshaft