Disassembling the Crankshaft Assembly

Special Tools
999 5746
999 5679

Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparation
Remove





- the oil trap.
- the Knock Sensors (KS).
- the front engine mounting.
- the oil pressure switch.

Remove





- the bearing retainer for the right drive shaft.
- the oil cooler and the rubber seals.

Removing the oil filter/oil pan





Remove the oil filter. Use tool 999 5679.
Remove the screws securing the oil pan to the intermediate section.
Carefully tap the side of the oil pan with a rubber mallet.
Lift out the oil pan.

Removing the oil pump suction pipe





Remove the O-rings from the oil ducts.
Remove the screws securing the suction pipe to the intermediate section.
Work loose/lift out the suction pipe.
Remove the suction pipe O-ring.
Check the pipe and the strainer.

Checking markings





Install the two old screws for the flywheel/carrier plate at the rear edge of the crankshaft.
Turn the crankshaft so the piston in cylinder 1 is at Bottom Dead Center (BDC).
Check that there are markings on the cap and connecting rods and check which way the markings are positioned (exhaust/intake side). Make a note of this.
If necessary mark with a center punch or a number punch, see Assembling The Crank Mechanism, refer to Reassembling Engine.

Removing the pistons from the cylinder block
Remove the screws for the connecting rod cover.
Lift out the cover. Check that the bearing cover comes with it.

Caution: The bearing covers are not interchangeable.





Install tool 999 5746 in the connecting rod and press out the connecting rod/piston.
Hold by hand so that the piston does not fall to the floor and ensure that the bearing cover comes with it.
Place the piston and connecting rod in such a way that they can be reinstalled in the correct cylinder.
Continue with cylinders 2, 3, 4 and 5 as above.

Caution: The bearing covers are not interchangeable.

Removing the screwed joint from the intermediate section
First remove the M7 screws from the intermediate section.
Then remove the M8 screws. Start at the outer edges and work alternately towards the center.





Remove the M10 screws in the same way.

Separating the intermediate section from the cylinder block





Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6 - 8 mm (0.2 - 0.3 inch).
Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.
Lift out the intermediate section. Check that the intermediate section bearing covers comes with it.

Caution: The bearing covers are not interchangeable. The crankshaft must not now be turned.

Ensure that the screws for the flywheel/carrier plate, which were installed earlier, are properly tightened. Lift them and the front of the crankshaft.
Carefully lift the crankshaft straight up.
Remove the remaining bearing covers.

Note! The bearing covers for the different bearing positions are not interchangeable.

Removing the nozzles for piston cooling





Remove the screws holding the covers.
Lift out the covers.
Remove the gaskets.
Pull out the nozzles for piston cooling.
Clean the gasket surfaces on the covers and cylinder block.

Cleaning
Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.





Use a razor blade or a gasket scraper and/or gasket solvent (P/N 116 1440).

Warning: A fume hood or extractor must be used when using gasket solution.