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Crankshaft Removing and installing

Crankshaft Removing and installing
Comprises
Oil sump Removing and installing
Fan (mounting on vibration damper) Removing and installing
Fan (mounting on coolant pump) Removing and installing
Belt drive Removing and installing
Vibration damper Removing and installing
Induction manifold Removing and installing
Coolant pipes Removing and installing
Coolant pump Removing and installing
Thermostat / thermostat housing Removing and installing
Turbocharger Removing and installing
Exhaust manifold Removing and installing
Cylinder head Removing and installing
Timing gears Removing and installing
Air compressor / steering booster pump Removing and installing
Timing chain housing Removing and installing
Crankcase yoke Removing and installing
Piston and connecting rod Removing

(1)
(2)
(3)
(4)

Crankshaft main bearing top

Crankshaft main bearing bottom
Crankshaft main bearing cap
Crankshaft main bearing bolt

(5)
(6)
(7)
(8)

Axial shim bottom

Crankshaft
Axial shim top
Crankcase

Technical data

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Crankshaft main bearing bolts (4)

Crankshaft main bearing bolts (4)
Connecting rod bearing bolts
Connecting rod bearing bolts

M14x118-10.9
M14x118-10.9
M11x1.5x60-11.9
M11x1.5x60-11.9

Crankshaft
Crankshaft hardness
Permitted curvature of journals
Crankshaft end play
Journal normal dimension
Journal normal dimension I
Journal repair level I
Journal repair level II
Journal repair level III
Journal repair level IV

Preliminary tightening 115 Nm

Final tightening 90 +10
Preliminary tightening 50 +10 Nm
Final tightening 90 +10

53 3 HRC
0.004 mm
0.150 0.282 mm
Diameter 76.981 77.000 mm
Diameter 76.781 76.800 mm
Diameter 76.481 76.500 mm
Diameter 75.981 76.000 mm
Diameter 75.481 75.500 mm
Diameter 74.981 75.000 mm

Crankshaft main bearing

Crankshaft main bearing wall thickness normal dimension (1) (2)
Crankshaft main bearing wall thickness normal dimension (1) (2)
Crankshaft main bearing wall thickness repair level I (1) (2)
Crankshaft main bearing wall thickness repair level II (1) (2)
Crankshaft main bearing wall thickness repair level III (1) (2)
Crankshaft main bearing wall thickness repair level IV (1) (2)
Axial shim normal dimension (5) (7)
Axial shim repair level I (5) (7)
Expansion

2.468 mm
2.518 mm
2.593 mm
2.718 mm
2.843 mm
2.968 mm
2.850 mm
3.100 mm
0.5 mm

Special tools
[1]

80.99612-0024

Socket 22 mm
Crankshaft bolts Tightening in conjunction with:
Support
Force multiplier spanner i = 1 : 3.3
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Washer

[2]

80.99619-0006

Force multiplier spanner i = 1 : 3.3

Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Washer
Socket 22 mm

[3]

80.99606-0551

Support
Crankshaft bolts Tightening in conjunction with:
Force multiplier spanner i = 1 : 3.3
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Washer
Socket 22 mm

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[4]

80.99607-0172

Angle measuring disc

Crankshaft bolts Tightening in conjunction with:
Support
Force multiplier spanner i = 1 : 3.3
Holding fixture
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Washer
Socket 22 mm

[5]

80.99606-0553

Holding fixture
Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Force multiplier spanner i = 1 : 3.3
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Washer
Socket 22 mm

[6]

06.02191-0407

Hexagon socket head cap screw

Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Holding fixture
Force multiplier spanner i = 1 : 3.3
Connecting pin
Rubber ring 42 mm
Washer
Socket 22 mm

[7]

06.22729-0006

Connecting pin
Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Force multiplier spanner i = 1 : 3.3
Rubber ring 42 mm
Washer
Socket 22 mm

[8]

08.06142-9006

Rubber ring 42 mm
Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Connecting pin
Force multiplier spanner i = 1 : 3.3
Washer
Socket 22 mm

[9]

80.99609-0033

Washer
Crankshaft bolts Tightening in conjunction with:
Support
Angle measuring disc
Holding fixture
Hexagon socket head cap screw
Connecting pin
Rubber ring 42 mm
Force multiplier spanner i = 1 : 3.3

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Socket 22 mm
[10]

08.71082-0005

Dial gauge
Crankshaft end play Checking in conjunction with:
Dial gauge holder

[11]

08.71000-3217

Dial gauge holder

Crankshaft end play Checking in conjunction with:
Dial gauge

Crankshaft Removing
Connecting rod bearing shells Removing

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Mark the connecting rod bearing shell (2) and connecting rod bearing (1) to indicate their installation
position and pairing
Unscrew the connecting rod bearing bolts
Remove the connecting rod bearing shell (2) with connecting rod bearing (1)
Push the piston and connecting rod out in the direction of the cylinder head

Special tool Assembling

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Fit the Holding fixture(5) with Hexagon socket head cap screw(4) and Washer(3) on the Support(2)
Place the Angle measuring disc(9) onto the Force multiplier spanner i = 1 : 3.3(1)
Place the Socket 22 mm(7) onto the Force multiplier spanner i = 1 : 3.3(1) and secure with the Connecting
pin(8) and Rubber ring 42 mm(6)

Crankshaft main bearing bolts Unscrewing

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Place the assembled special tool (1) onto the bolt that is going to be unscrewed
Crankshaft main bearing bolts Unscrewing all

Crankshaft main bearing Removing

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Remove the crankshaft main bearing bolts (1)

Remove the crankshaft main bearing shell (2) with crankshaft main bearing (3)

Crankshaft Lifting out

WARNING
The crankshaft can be damaged
l Do not use any lifting gear with sharp edges to lift out the crankshaft
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Use lifting gear to lift the crankshaft (2) out of the crankcase (1)

Crankshaft main bearings Checking

Crankshaft main bearings Checking for expansion

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Clean the crankshaft main bearings (2) and put them together on a flat surface as marked
Use a micrometer gauge to check dimension A
Use a micrometer gauge to check dimension B
The difference between dimension A and dimension B is the expansion of the crankshaft main bearings
The maximum permitted expansion is 0.5 mm

Crankshaft main bearing inside diameter Checking

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Insert the crankshaft main bearing into the crankshaft main bearing seat and crankshaft main bearing cap
(3) as marked
Insert the crankshaft main bearing cap (3) into the crankcase as marked
Tighten the crankshaft main bearing bolts
Use the internal calliper (2) and Dial gauge(1) to measure the inside diameter of the crankshaft main
bearing
Repeat the measurement at various points, dimensions Technical data
Remove the crankshaft main bearing cap (3) after the measurement

Crankshaft Checking

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Clean the journals of the crankshaft (2)

Use a micrometer gauge (1) to measure the crankshaft journal
Repeat the measurement for each journal
Dimensions, Technical data

Crankshaft Installing
Crankshaft Inserting

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Insert the crankshaft main bearing shells into the crankcase (1) as marked
Use lifting gear to lift the crankshaft (2) into the crankcase (1)

Upper axial shims Installing

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Note
The axial shims of the crankshaft main bearings are installed in the fourth bearing seat.
Make sure the installation orientation and installation position are correct.
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Push the upper axial shims (2) between the crankcase and crankshaft at crankcase bearing 4 with the oil
grooves pointing towards the crankshaft (1)
Screw the axial shims (2) into the bearing seat by pressing slightly

Lower axial shims Installing

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Insert the axial shims (1) and (4) into the crankshaft main bearing cap (2) with the oil grooves pointing
towards the crankshaft
Place the crankshaft main bearing cap (2) onto the bearing seat and fix it
Screw in the crankshaft main bearing bolts (3) until finger-tight

Crankshaft end play Checking

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Place the Dial gauge(1) and Dial gauge holder(2) onto the crankcase
Place the dial gauge probe onto the crankshaft (3), push the crankshaft (3) into an end position and zero
the Dial gauge(1)
Push the crankshaft (3) to the other end position and read off the difference on the Dial gauge(1)
Thickness of axial shims Technical data

Special tool Assembling

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Fit the Holding fixture(5) with Hexagon socket head cap screw(4) and Washer(3) on the Support(2)
Insert the Force multiplier spanner i = 1 : 3.3(1) into the Support(2)
Place the Angle measuring disc(9) onto the Force multiplier spanner i = 1 : 3.3(1)
Place the Socket 22 mm(7) onto the Force multiplier spanner i = 1 : 3.3(1) and secure with the Connecting
pin(8) and Rubber ring 42 mm(6)

Crankshaft main bearing bolts Tightening

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Note
Note the multiplication ratio of the force multiplier spanner i = 1 : 3.3

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Place the assembled special tool (1) onto the flywheel bolt that is going to be tightened
Tighten the mounting bolts to Preliminary tightening 115 Nm
Tighten the mounting bolts to Final tightening 90 +10

Connecting rod bearing shell Fitting

WARNING
Crack surfaces are sensitive, pitting corrosion may occur as a result of the principle
involved
l Replace the connecting rod if the crack surfaces on the connecting rod are damaged
l Protect crack surfaces against damage by hard and sharp objects
l Only clean crack surfaces on the connecting rods by washing in clean cleaning agent
l Dry crack surfaces with compressed air after cleaning
l Make sure washed-out particles do not get into the engine
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Insert the connecting rod bearing (1) into the corresponding connecting rod bearing shell (2) according to
the marking and pairing
Line up the connecting rod bearing shell (2) exactly on the connecting rod and bring it into contact, taking
care not to damage the contact surfaces between the connecting rod bearing shell and connecting rod

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Screw in new connecting rod bearing bolts by hand

Tighten the connecting rod bearing bolts to Preliminary tightening 50 +10 Nm
Tighten the connecting rod bearing bolts to Final tightening 90 +10

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