Removal and Installation

PRECEDING WORK
Engine removed.
Guide rails in cylinder heads removed.
Tensioning rail removed.
Guide rail in crankcase removed.
Oil pump removed.
End cover removed.

OVERVIEW






NOTES:
The 7 crankshaft bearing caps manufactured from malleable cast iron are fitted at the side into the crankcase. The fit is off-centered so that the bearing caps can only be installed in one position.
The 5 middle bearing caps are additionally bolted to the side walls of the crankcase.
The crankshaft bearing caps are machined together with the crankcase.
If bearing damage has occurred, the conrods must be removed and any swarf in the conrod bores and crankshaft oil passages must be removed.
Carefully clean the oil passages in the crankcase, crankshaft, timing case cover, oil filter housing, end cover, oil pump, etc.

REMOVING, INSTALLING
1 Take timing chain off camshaft sprockets and crankshaft sprocket and remove
2 Remove oil pump chain together with tensioning rail, tensioning spring, and sleeve
3 Unscrew oil deflector plate at crankcase and remove
Tightening torque 9 Nm.
4 Unscrew conrod bearing caps and remove.
5 Unscrew crankshaft bearing caps and remove.
6 Remove crankshaft.





7 Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil the bolt thread and head and the contact surface of the nut.
Tightening torque:
Nuts
M8 x 1: 30 Nm
M10 x 1: 50 Nm.
Side bolts
M8 x 60: 30 Nm.

NOTE: Pay attention to marking, 1 is to the front. The fit is off-centered, the crankshaft bearing caps can only be installed in one position. Use bolts of quality 10.9 for the side bearing cap bolted connection.





8 Lubricate conrod bearing shells with SAE 30 engine oil and install bearing caps.
Pay attention to marking (arrow)!
Install the bearing shells with the oil passage in the conrod otherwise the conrod bushes will not be lubricated.





9 Tighten conrod bolts.





10 Measure axial conrod bearing play. Check clearance of conrods in piston.
Disassemble oil pump, clean, replace if necessary. Replace oil pressure valve. Replace oil filter, carefully clean air-to-oil cooler or replace.


SPECIAL TOOLS