Assembling Crankshaft

Assembling crankshaft

1. Clean crankshaft thoroughly.
2. Rinse out oil bores with a hand pump and solvent naphtha several times.
3. With a visual inspection, check whether the oil ducts are blocked at the bearing surfaces and on the front face (aluminium stoppers).
4. Clamp crankshaft.







5. Lubricate the con-rod journals with grease (Optimal Optipit) and mount the connecting rods on the crankshaft.







NOTE: The matching numbers of the con-rods and the con-rod bearing caps must all point to the same side.


6. Tighten con-rod nuts.







7. After the tightening procedure, check the con-rod bolt for twisting.
8. Insert and align new Woodruff key for timing gear.


NOTE:
- The collar of the timing gear must point to bearing 7.







- As an assembly aid, remove the timing gear from the heat source e.g. with a piston restraining strap and quickly mount or push it into place on the journal.


9. Warm the timing gear to approx. 150 - 200 °C in an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop.
10. Heat up the spacer ring in the same way and push it on up to the stop.
11. Mount snap ring.


NOTE: The snap ring must be inserted without play.


The following snap rings are available:













12. Select the corresponding snap ring using an insertion test.
13. The opening of the snap ring should lie opposite the Woodruff key groove.












14. Knock the snap ring into the retaining groove with a blunt chisel.