Crankshaft
Removing and installing crankshaftTools
Preliminary work
1. Remove pistons.
2. Remove front crankshaft belt pulley.
3. Remove timing chains.
Information
Component overview
Removing crankshaft
ATTENTION Damage to sensitive engine components (e.g. speed sensor wheel)
^ Conscientious and precise work
^ Use suitable storage places.
1. Remove the joint flange at the front behind the belt pulley. Do this by removing all the fastening screws and carefully levering out the joint flange. Clean sealing faces.
Note:
^ Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.
^ Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
^ The twist locks or retaining lugs are on the same side.
^ Bearing screws must be replaced.
^ Bearing shells must be replaced. Use only identical color markings
2. Dismantle all bearing covers from the crankshaft. Bearing covers and shells are assigned to specific cylinders and should be set aside on a clean surface where they will not get mixed up. For bearing cover no. 5, carefully remove the thrust washers at the side.
ATTENTION Risk of cutting or squashing by heavy components with sharp edges (crankshaft)!
^ There is a danger of injury to hands when inserting the crankshaft.
^ Hold the very outside of the crankshaft.
^ Wear gloves.
^ Allow an assistant to help lift the crankshaft.
Note: Prepare a suitable storage space for the crankshaft so that the speed sensor wheel is not damaged.
3. With the help of assistants, carefully lift the crankshaft out of the cylinder block and set aside on a soft, clean surface so that the sensor wheel is not damaged.
Installing crankshaft
1. Replace bearing shells and thrust washers. When replacing bearing shells make sure that the color markings match.
2. Insert bearing shells into the bearings and bearing covers after oiling them. Insert twist locks or retaining lugs for the bearing shells into the recesses. Make sure the twist locks are positioned correctly.
ATTENTION Risk of cutting or squashing by heavy components with sharp edges (crankshaft)!
^ There is a danger of injury to hands when inserting the crankshaft.
^ Hold the very outside of the crankshaft.
^ Wear gloves.
^ Allow an assistant to help lift the crankshaft.
3. Carefully insert the crankshaft into the cylinder block with the help of an assistant. Test once again that the bearing shells and thrust washers are correctly positioned (they can easily shift out of place). Oil crankshaft journals.
Note:
^ Bearing covers for the crankshaft are numbered 1 to 7 and the numbers can be read on the side facing the exhaust.
^ Bearing no. 5 is a guide or thrust bearing with two thrust washers at the side.
^ The twist locks or retaining lugs are on the same side.
^ Bearing screws must be replaced.
^ Bearing shells must be replaced. Use only identical color markings
4. Replace fastening screws for bearing covers. Attach all bearing covers to the crankshaft. Bearing covers and shells should be oiled and installed so that the twist locks or retaining lugs are on the same side.
5. Insert sickle-shaped washers into bearing cover no. 5 (make sure there is axial play in the bearings). Insert the two sickle-shaped washers (thrust washers) to the left and right of bearing cover no. 5 with a certain amount of grease so that the washers do not fall down. Each of the lubricating grooves of the sickle-shaped washers must face outwards. Assemble bearing cover no. 5 along with the greased thrust washers.
6. Pull out all the bearing cover fastening screws diagonally outward from the middle Initial tightening: 30 (22 ft-lb.) Nm Final tightening: 180°.
Note: Lubricant must be applied thinly to the inside of the bore.
7. Install joint flange at the front behind the pulley. To do this clean sealing faces. Apply silicon sealant 000.040.300.39 thinly and evenly on the sealing faces of the joint flange. Mount joint flange immediately and fit fastening screws. Tighten fastening screws evenly. Tightening torque: 10 (7.5 ft-lb.) Nm
Note: The crankshaft sealing ring for the pulley was changed in model year 2005 as of engine number BFD20319. This crankshaft sealing ring is now permanently integrated in the joint flange and can no longer be changed as a separate item. If there is a leak, the complete joint flange must be replaced.
8. The sealing faces must all be clean and free of grease.
9. Apply sealant 000 043 300 39 as shown in the illustration-arrows-. Ensure that the bead of sealant is no thicker than approx. 2 to 3 mm and is run past the bores on the inside. Mount the joint flange within five minutes.
10. Push front of special tool (guide sleeve) assembly fixture T10215 onto the crankshaft journal. Slide joint flange over the guide sleeve and into the installation position.
11. Screw down joint flange. Tightening torque: 10 (7.5 ft-lb.) Nm
Replacing speed sensor wheel
Replacing pick-up (sensor) wheel
1. Remove the crankshaft and set it aside so that the speed sensor wheel is easily accessible and is not in contact with the shaft.
2. Loosen the fastening screws -1 and 2-. Carefully remove the speed sensor wheel.
3. Clean the attachment surfaces Smear the attachment surfaces thinly with medium locking agent.
4. Immediately position a new speed sensor wheel on the crankshaft and align it. Align the VR6 marking to the individual bore on the crankshaft. Apply medium-tight screw locking agent to all fastening screws with and tighten the screws hand-tight. Tighten the fastening screw -1- first. Insert Initial tightening: 7.5 ft-lb. Insert Final tightening: 90° Then tighten the screw -2- firmly. Insert Initial tightening: 7.5 ft-lb. Insert Final tightening: 90°.
5. Install crankshaft.
6. Check whether the gap in the teeth of the speed sensor wheel points downwards in the top dead center position -arrow-. At the same time, the ground tooth of the crankshaft sprocket must align with the joint face of the bearing cover -B-.
Subsequent work
1. Replace sealing ring on pulley.
2. Install pistons.
3. Fit timing chains.