Removal and Installation Crankshaft

Removing and installing crankshaft

Removing and installing crankcase and bearing housing with crankshaft

Removal

1. Detach thrust plate or flywheel. Fasten toothed segment (special tool 9538/1) on the crankcase half (cylinder bank 1 - 3) with hexagon-head bolt M12 x 50.
2. Detach thrust plate and remove with drive plate. Detach and remove the flywheel.

3. Clamp crankcase. Fasten engine holder, special tool 9589, to the crankcase half of cylinder bank 1 - 3.

4. Turn primary chain tensioner out of the crankcase (cylinder bank 4 - 6).

5. Loosen belt pulley. Undo hexagon-head bolt (M16 x 1.5 x 60) with special tool (socket wrench insert 9594); to do this, hold with holding device (special tool 9593).

6. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the locknut using the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin.

7. Remove coolant guide housing.

8. Undo fastening screws between crankcase half of cylinder bank 1 - 3 and bearing housing.

9. Undo fastening screw between crankcase half of cylinder bank 4 - 6 and bearing housing.
10. Turn crankcase by 180°. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer. Remove air-oil separator.
11. Turn crankcase 90° further. Crankcase half of cylinder bank 4 - 6 faces upward. Undo hexagon-head bolts (M6 x 35, 25 ea.) joining the crankcase halves.

12. Carefully lift the crankcase half up and off. Do not tilt - this might damage the pistons.

13. Mark pistons. Lever off front piston pin circlip. Push out piston pin.

14. Fasten assembly fixture (special tool 9607) on the bearing housing with two M10 x 20 hexagon-head bolts.

15. Fasten suspension eye, attach spring hook, and lift bearing housing out of the crankcase half using a workshop crane or engine lifter.
16. Disassemble bearing housing on intermediate shaft.