Crankcase Disassembling

Disassembling crankcase













Tools


Adapting engine holder

Note!
The threaded bores must only be provided if the adapter ring is used for the first time.




Sequence 1 - 6




Procedure and Instructions





1. Centring adapter on engine holder. Fasten the adapter half with the already made bores -arrows- with two auxiliary screws M1O x 60 onto the engine holder. Spot-drill or countersink the engine holder slightly through the bores in the adapter ring using a drill bit 6.5mm. The adapter ring serves as the drilling template.





2. Rework engine holder. Drill a pilot hole for an M6 thread on the countersunk points. To do this, first drill with a drill bit 3mm, then with a drill bit 5mm.





3. Drill pilot hole and cut thread.





4. Fasten adapter on engine holder. Fasten adapter with the supplied cylinder screws onto engine holder with hexagon socket (M6 x 35).





5. Mount engine holder with adapter half. Screw engine holder with screwed in adapter half onto the crankcase half of the cylinder bank 4 - 6.





6. Mount the second adapter half on crankcase. Screw the screw sleeves onto the studs and tighten by hand. Screw in connecting screws of the adapter half and tighten with 10 Nm (7.5 ftlb.). Subsequently tighten the assembly sleeves.


Left crankcase half (cylinder bank 1 - 3)




Component View







Designations and Notes

Right crankcase half (cylinder bank 4 - 6)




Component View







Designations and Notes


Disassembling the crankcase

Note!
The thrust plate, drive plate and the flywheel must be removed before fastening the engine onto the engine holder or assembly support





1. Position the toothed segment special tool P201b on the stud and undo the pan-head screws of the clutch pressure plate in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate.





2. Fasten mounting device P238b with holder P14O onto the studs. Loosen flywheel screws and remove the flywheel. Make sure that the pulse sender is not damaged.

Note!
If the engine holder special tool (adapter ring) 9667 is used for the first time 2 threaded bores must be made in addition.

3. Mount engine holder. See also sub-section "Adapting engine holder".

Note!
^ The pulse sender should not be detached!
^ Shear bolts were installed in the first vehicles.




Shear bolts on pulse sender

4. The shear bolts are replaced by micro-encapsulated hexagon head bolts M6 x 20.




Hexagon head bolts on pulse sender





5. Loosen belt pulley. To do this, a second person should counter with the holding wrench 9548 at the same time. Do not continue to use the hexagon-head bolt.

6. Loosen the 18 hexagon nuts (M8) of the housing screw connections.





7. Loosen the hexagon nuts (wrench size 17) in the left crankcase half (cylinder bank 1-3).





8. Loosen tension rod bolts from the outside to the inside.

Note!
The tension rod bolts in thrust blocks 2, 3, 4 and 5 -arrows- can only be removed after removing the crankcase half (cylinder bank 1-3).

Removing tension rod bolts.





9. Crankcase half (cylinder bank 1-3).





10. Remove O-rings and tension rod bolts of thrust blocks 2, 3, 4 and 5.