Installing Crankshaft

Information 

Allocation of crankshaft bearing shells for cylinder block: 

Bearing shells of the correct thickness are allocated to the cylinder block at the factory. Coloured dots on the side of the bearing shell are used to identify bearing shell thickness.

The allocation of bearing shells to the cylinder block is also indicated by a letter at right of the cylinder block -Arrows-  .

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Allocation of crankshaft bearing shells for cylinder block

Information 

Allocation of crankshaft bearing shells for bearing covers: 

• Bearing shells of the correct thickness are allocated to the bearing covers at the factory Coloured dots on the side of the bearing shell are used to indicate bearing shell thickness. 
• The allocation of bearing shells to the bearing covers is indicated by a letter on the front crankshaft flange as shown. 
• The series of letters begins with crankshaft bearing "5" (on transmission side) and ends with crankshaft bearing "1" (on pulley side). 

Information 

Observe marking for the bracing gear wheel to the crankshaft.

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Allocation of crankshaft bearing shells to bearing covers

1. Install new bearing shells with correct colour markings.
   1. 1.1 Coat bearing shells with oil.
   2. 1.2 Insert bearing shells on the relevant crankshaft bearing and bearing cover.
      1. 1.2.1 Check that the guide lugs are fitted correctly.

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   Bearing shell

2. Insert crankshaft.
   1. 2.1 Carefully insert crankshaft into the crankcase with the help of another person.
   2. 2.2 Insert thrust washers at the 4th crankshaft bearing.
   1. 2.2.1 Please note: Lubricating grooves must be facing the crankshaft! 
   2. 2.2.2 Coat thrust washers with oil.
   3. 2.2.3 Insert upper thrust washer (crankcase).
   4. 2.2.4 Position lower thrust washer (bearing cover) in the bearing cover.

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   Thrust washers on crankshaft bearing 4

3. Install bearing cover.
   1. 3.1 Check that bearing shells are seated correctly in the bearing cover.
   2. 3.2 Check dowel sleeves for damage and check that they are fitted correctly.
   3. 3.3 Move bearing cover into installation position.
   4. 3.4 Fit screws -1 to 30-  and tighten according to the specified tightening sequence.
   Fig 1: Bearing Cover Tightening Sequence

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   Tightening sequence for bearing cover

   Tightening specifications for crankcase/bearing saddle 

   Screw	Steps	Tightening torque
   1-20	Step 1:/Fit	> Tightening torque 15 Nm (11 ftlb.)
   1-20	Step 2:	> Tightening torque 30 Nm (22 ftlb.)
   1-20	Step 3:	> Torque angle + 200°
   1-20	Step 4:/Loosen by 2 turns	> Torque angle 720°
   1-20	Step 5:	> Tightening torque 30 Nm (22 ftlb.)
   1-20	Step 6:	> Torque angle 70°
   21-30	Step 7:	> Initial tightening 10 Nm (7.5 ftlb.)  > Final tightening + 50°