Assembling the Crankcase

1. Fasten engine support P201 on the right crankcase half (cylinder bank 4 - 6)







2. Check the matching number of the crankcase halves. The number is at the top on the lug.


NOTE: The tolerance groups are 0 and 1


3. Allocate the crankshaft gearwheel and the intermediate shaft to the crankcase. The tolerance group number is stamped on the crankcase -arrow- and must must be identical to that of the intermediate shaft gearwheel and crankshaft gearwheel.





Matching number on the crankcase






Matching number on the crankshaft gearwheel -arrow-






Matching number on the intermediate shaft gearwheel -arrow-

4. Clean crankcase halves thoroughly. Examine the take-up bores of the tension rod bolts for foreign objects (e.g. seal remnants).







5. Fit intermediate-shaft bearings. Place new bearing shell halves into the crankcase half of cylinder bank 4 - 6.







6. Oil the bearing surfaces. Insert intermediate shaft and check for true running.

7. Insert new crankshaft bearing shell halves into the crankcase.
Oil the bearing surfaces.







8. Check whether the dowel sleeves are present and seated properly.

9. Place crankshaft (without bearing 8) into the crankcase half of cylinder bank 4 - 6.


NOTE: If the wear dimension has been reached, the intermediate shaft and the matched drive gearwheel must be replaced.







10. Check circumferential backlash of the intermediate shaft. Fasten a dial-gauge holder, e.g. VW 387, onto the crankcase joint surface for this purpose. The sealing surface must not be damaged when this is done. Align the dial gauge on a tooth face and measure the backlash. Then turn the intermediate shaft by 180° and repeat the measurement.

Circumferential backlash:
New dimension: 0.035 - 0.084 mm
Wear dimension: 0.10 mm

11. Remove intermediate shaft again.

12. Have a second person lift the crankshaft slightly, and slide bearing No. 8 onto the crankshaft journal.







13. Lower the crankshaft slowly and insert crankshaft bearing No. 8 into the locating pin.







14. Check the installation position. If the part is fitted correctly, the centre of the bearing notch must lie in the plane of the sealing surface.


NOTE: Oil sealing lip






Inserting crankshaft sealing ring into the crankcase.







15. Grease the sealing ring (19.5 x 26) on both sides and insert it into the crankcase half 4 - 6 in the area of the oil pump mount.

16. Insert the complete unit, oil pump with dumb-bell shaft and intermediate shaft with both timing chains into the crankcase half.







17. Fasten new collar nuts (3 ea.). Tightening torque 23 Nm (17 ftlb.).







18. Check dumb-bell shaft. The dumb-bell shaft must be easily movable in axial direction. If necessary, loosen the oil pump with the intermediate shaft again and shift the dumb-bell shaft.


NOTE:
- O-rings are additionally fitted on 4 tension rod bolts of the bearing support mount, bearing supports 2, 3, 4 and 5.
- The 4 tension rod bolts must always be fitted before the crankcase halves are joined.







19. Prepare tension rod bolts for installation. The illustration shows the already mounted tension rod bolts in the designated bearing supports.


NOTE:
- Oil the sealing rings only immediately prior to fitting them.
- Do not store the sealing rings in oiled state.







- Prepare four tension rod bolts. Push sealing washers onto the tension rod bolts. Guide lightly oiled O-rings over the threaded area using the conical sleeve of special tool 9511 and push them to the tapered section towards the head of the bolt.







- Observe A side and B side of assembly sleeve 9511.







- Push the prepared tension rod bolts into the right crankshaft housing half from below. Push them in as far as they will go and hold them in this position.







- Place conical sleeve on end of the thread. Push O-ring (dry) over the conical sleeve. Remove conical sleeve and push the O-ring with the cylinder sleeve as far as the chamfer in the bearing support. Remove cylinder sleeve.






Use of cylinder sleeve







20. Fix connecting rods of cylinders 4, 5 and 6 in upright position with restraining straps (special tool P221). Fix timing chain in upright position with the restraining strap.







21. Apply Vaseline on both sides of the sealing rings for the oil pump (2 ea.) and the sealing ring for the crankcase and insert the rings.







22. Prepare crankcase halves of cylinder bank 1 - 3. Insert the bearing shells of the crankshaft and of the intermediate shaft.
- Degrease the sealing surfaces of the crankcase halves. Apply a uniform bead of silicone (Drei Bond type 1209) approximately 1.5 mm wide to the sealing surface of the crankcase half of cylinder bank 1 - 3.












- Check for foreign objects, e.g. silicone residues, in the relief groove in the area of the main bearing No. 7 and remove them if necessary.
- Insert the crankcase half carefully over the prefitted tension rod bolts of bearing supports 2, 3, 4 and 5, at the same time having a second person pull the chain upwards through the chain space.

23. Remove restraining straps again.


NOTE: Always replace the fastening nuts







24. Join the crankcase halves and secure them with approx. 6 new fastening nuts with washers. Distribute the fastening nuts uniformly around the perimeter and tighten them by hand.







25. Insert and hold the prepared tension rod bolts from crankcase half 4 - 6.







26. Push the conical sleeve of special tool 9511 with an oiled O-ring onto the end of the thread.







27. Using the A side (thin wall) of the cylinder sleeve, carefully push the O-ring off the conical sleeve.






View of the conical sleeve


28. Remove conical sleeve and carefully push round seal to its end position with the B-side (thick wall) of the cylinder sleeve, while bracing the bolt head.

29. Mount sealing washers (dry) and press down slightly with B-side of cylinder sleeve.

30. Screw on multiple-tooth nuts (thread oiled) by hand.

31. Proceed in the same way with the two studs of crankcase half 4 - 6 (area of bearing 1) on the flywheel side.


NOTE: During assembly, briefly cover the chain space to prevent parts from falling into the crankcase.







32. Mount hexagon nut M10 x 1.25 and washer A10.5 on stud, with rounded side pointing towards the hexagon nut.

33. Mount retaining device (special tool 9662) on corresponding tension rod bolt and position with holder (special tool P140).


NOTE:
- If the tension rod bolts are tightened without retaining device 9662, a second person should always counter them.
- The O-ring will be damaged if the tension rod bolt turns.
- Use a 14 mm Snap-On multiple-tooth socket nut to counter.






Retaining device 9662







34. Tighten tension rod bolts or studs to 50 Nm (37 ftlb.). Observe the tightening sequence.







35. Tighten tension rod bolts on the flywheel side to 50 Nm (37 ftlb.).







36. Fit a new self-locking hexagon nut (No. 15) with washers and tighten to 50 Nm (37 ftlb).


NOTE: Self-locking nuts must always be replaced.







37. Fit remaining crankcase screws. Tighten the hexagon nuts to 23 Nm (17 ftlb.).


CAUTION:
Danger of injury
- The holding wrench must be in contact with the vibration damper when tightening.







38. Always replace the belt pulley fastening screw. When the belt pulley is tightened, a second person should counter with special tool 9548. The vibration damper is tightened to 235 Nm (174 ftlb.).

39. Fit flywheel.

40. Turn vibration damper or crankshaft to TDC of cylinder 1 or 4.

41. Subsequently fit pistons or cylinders (see Removing and Installing Pistons).