AR03.20-W-4351G Remove/install crankshaft 23.9.

10
ENGINES 541.9 in MODEL 930, 932, 933, 934
ENGINES 542.9 in MODEL 930, 932, 934

Shown on engine 541.9

1 Crankshaft
2 Main bearing shell
3 Main bearing shell
4 Thrust plate fitted bearing
5 Main bearing cap
6 Main fitted bearing cap
7 Main bearing cap central bolt
8 Side bolt for main bearing cap
9 Crankshaft sprocket

L Shank length

W03.20-0017-06

W03.20-1099-09

Shown on engine 541.9

1 Crankshaft 5 Main bearing cap 11 Drift

2 Main bearing shell 6 Main fitted bearing cap
3 Main bearing shell 9 Crankshaft sprocket Arrows Markings
4 Thrust plate fitted bearing 10 Camshaft sprocket

Modification notes
23.6.10 Work procedure changed.

Removing
1.2 Remove engine with transmission Only model 934 without code (MP1) Rear AR01.10-W-2401G
cooling system or without code (G02) Torque
converter clutch (WSK)
Only model 934 with transmission 715.5 AR01.10-W-2401GA
with code (MP1) Rear cooling system and
with code (G02) Converter shift clutch (WSK)
2 Remove timing case Engine 541.9, AR01.60-W-8200GA
engine 542.9 with code (MS4) BlueTec 4 or
with code (MS5) BlueTec 5
Engine 542.9 without code (MS4) BlueTec 4 AR01.60-W-8200GB
or without code (MS5) BlueTec 5
3 Remove oil pump AR18.10-W-6020G
4 Remove front housing cover AR01.40-W-8800G
5 Remove pistons AR03.10-W-7021G
6 Remove main bearing cap (5) and main fitted Check whether the marking of the main
bearing cap (6) bearing cap (5) is present, if necessary mark
the main bearing cap (5).
7 Remove main bearing shells (3) from main Identify main bearing shells (3) to
bearing caps (5) and from main fitted bearing respective main bearing cap (5) and to main
cap (6) fitted bearing cap (6).
8 Remove fitted bearing thrust plates (4) from
main fitted bearing cap (6)
9 Push fitted bearing thrust plates (4) at fitted
bearing of crankshaft (1) out of crankcase
10 Lift crankshaft (1) out of crankcase using a Screw drifts (11) into crankshaft (1)
lifting cradle and place down to one side at front and rear and secure shackle on it.
Drift *403589026300
11 Remove main bearing shells (2) from Mark main bearing shells (2) relative to
crankcase the crankcase.
12 Clean crankshaft (1) and oil duct in
crankshaft (1)
Check
13 Check grooved pins for fitted bearing thrust If grooved pins are damaged:
plates (4) at main fitted bearing cap (6)
Replace grooved pin at main fitted bearing AR01.40-W-8600-01G
cap.
Protrusion of grooved pin to main bearing *BE01.40-N-1003-02C
cap
14 Check crankshaft (1) by means of visual If there is damage or cracks:
inspection for damage and cracks
Replace crankshaft (1).
15 Clean main bearing shells (2, 3), thrust plates
of fitted bearings (4) and main bearing
journals of crankshaft (1) with a chamois
leather and check by a visual inspection
Information on assessing wear of main AH03.20-N-1000-02A
bearings and main bearing journals
16 Measure concentricity of crankshaft (1) at On engine 541.9, measure at both center AR03.20-W-4351-08G
middle main bearing journal main bearing journals.
On engine 542.9, measure at center main
bearing journal.
*BE03.20-N-1007-02C
Dial gage *001589532100
Dial gauge holder *363589022100
17 Inspect hardness of main and connecting rod AR03.20-W-4351-09G
bearing journals
Hardness of main bearing and connecting *BE03.20-N-1009-02C
rod journals
Hardness tester *000589202100
Notes on hardness test AH00.00-N-0012-01A
18 Determine crankshaft bearing radial play AR03.20-W-4291-02G
Main bearing cap central bolt *BE01.40-N-1002-02C
Main bearing journal dia., main bearing *BE03.20-N-1001-02C
journal width (except main bearings/fitted
bearing journals)
Main bearing journal dia., fitted bearing *BE03.20-N-1002-02C
journal width
Crankshaft main bearing inside dia. when *BE03.20-N-1012-02C
installed
Main bearing radial play *BE03.20-N-1015-02C
Main bearing cap central bolt *BA01.40-N-1013-01D
Main bearing cap side bolt *BA01.40-N-1016-01D
19 Determine connecting rod bearing radial play AR03.20-W-4291-04A
Connecting rod bearing inside dia. for *BE03.10-N-1001-01C
connecting rod bearing shells inserted
Bolt of connecting rod bearing cap to *BE03.10-N-1005-01C
connecting rod
Connecting rod bearing radial play *BE03.10-N-1006-01C
Connecting rod journal dia., connecting rod *BE03.20-N-1004-02C
journal width
*BA03.10-N-1001-01C
Dial indicator *001589532100
20 Determine thickness of fitted bearing thrust AR03.20-W-4351-01G
plate (4) at crankshaft (1)
Main bearing journal dia., fitted bearing *BE03.20-N-1002-02C
journal width
Wall thickness of fitted bearing thrust plates *BE03.20-N-1013-02C
Dial indicator *001589532100
21 Measure central bolts of main bearing cap If permissible shank length (L) is *BE01.40-N-1002-02C
(7) exceeded:

Replace respective central bolt of main

bearing cap (7).
Install
22 Remove any metal abrasion from oil ducts Only if bearing damage has occurred.
and clean the inner components
23 Insert main bearing shells (2) with groove The oil holes of the main bearing shell
into crankcase (2) must match with the oil holes in the
cylinder crankcase, otherwise bearing
damage can occur.
Observe identification of main bearing
shells (2) to crankcase. Lubricate contact
surfaces of main bearing shells (2) with
engine oil.
24 Put crankshaft (1) with shackle onto main Markings (arrows) on crankshaft gear (9)
bearing shells (2) in crankcase and camshaft sprocket (10) must be
positioned opposite each other.
Screw in second drift ( 11) or second bolt
into one of the threaded holes in crankshaft
(1), if necessary, and turn crankshaft (1)
using a suitable lever.
Drift *403589026300
25 Remove drift (11) and shackle from
crankshaft (1)
26 Insert fitted bearing thrust plates (4) between Lubricate fitted bearing thrust plates (4)
crankshaft (1) and crankcase with engine oil. Grooves in fitted bearing
thrust plates (4) must point towards the
crank webs.
27 Insert main bearing shells (3) into main Lubricate contact surfaces of main
bearing cap (5) and main fitted bearing cap bearing shells (3) with engine oil. Observe
(6) identification of the main bearing shells (3) to
respective main bearing cap (5) and to main
fitted bearing cap (6). Retaining lug at main
bearing shell (3) must be inserted into
groove provided for this purpose.
28 Attach fitted bearing thrust plates (4) to main Lubricate fitted bearing thrust plates (4)
fitted bearing cap (6) with engine oil. Grooves in fitted bearing
thrust plates (4) must point towards the
crank webs. The thrust plates of the fitted
bearings (4) are fixed in place by bores in
the grooved pins on the main/fitted bearing
caps (6).
29 Install main bearing cap (5) and main fitted Main bearing cap (5) and main fitted
bearing cap (6) with fitted bearing thrust bearing cap (6) have dowel pins and are
plates (4) marked with numbers and must be installed
according to numbers (e.g. 1x xxx),
beginning at the front, in an ascending order.
30 Lubricate central bolt of main bearing cap (7)
and side bolt of main bearing cap (8) with
engine oil
31 Tighten main bearing cap (5) and main fitted First tighten central bolts of main bearing
bearing cap (6) cap (7) and then tighten side bolts of main
bearing cap (8).
Central bolt for main bearing cap *BA01.40-N-1013-01D
Side bolt for main bearing cap *BA01.40-N-1016-01D
32 Rotate crankshaft (1) by hand and check for
33 Determine crankshaft bearing crankshaft end AR03.20-W-4291-03G
play (1)
Main bearing axial play *BE03.20-N-1006-02C
Dial indicator *001589532100
Dial indicator holder *363589022100
34 Perform additional checking work for engine AR03.20-W-0002A
repair on crankshaft (1)
35 Install pistons AR03.10-W-7021G
36 Install oil pump AR18.10-W-6020G
37 Install front housing cover AR01.40-W-8800G
38 Install timing case Engine 541.9, AR01.60-W-8200GA
engine 542.9 with code (MS4) BlueTec 4 or
with code (MS5) BlueTec 5
Engine 542.9 without code (MS4) BlueTec 4 AR01.60-W-8200GB
or without code (MS5) BlueTec 5
39.1 Install engine Model 930, 932, 933, 934 AR01.10-W-2400G
39.2 Install engine with transmission Only model 934 without code (MP1) Rear AR01.10-W-2401G
cooling system or without code (G02) Torque
converter clutch (WSK)
Only model 934 with transmission 715.5 AR01.10-W-2401GA
with code (MP1) Rear cooling system and
with code (G02) Converter shift clutch (WSK)

Check values for crankcase

Number Designation Engine 541.9,

542.9

BE01.40-N-1002-02C Main bearing cap central bolt Thread diameter M 18

Length of shank when mm 173

new

Permissible shank length mm 176

BE01.40-N-1003-02C Protrusion of grooved pin to main mm 4.5 to 4.7

bearing cap

Number Designation Engine Engine

541.9, 542.9
from engine from engine
end no. 054766 end no. 054766

BE03.10-N-1001-01C Connecting rod bearing inner Default mm 94.064 to 94.110 94.064 to 94.110
diameter for connecting rod bearing
shells inserted

Deviation 0.10 mm 93.964 to 94.010 93.964 to 94.010

Deviation 0.25 mm 93.814 to 93.860 93.814 to 93.860

Deviation 0.50 mm 93.564 to 93.610 93.564 to 93.610

Deviation 0.75 mm 93.314 to 93.360 93.314 to 93.360

Deviation 1.00 mm 93.064 to 93.110 93.064 to 93.110

BE03.10-N-1005-01C Bolt, connecting rod bearing cap to Thread diameter M 16 1.5 16 1.5
connecting rod

Permissible shank mm 74.5 74.5

length

BE03.10-N-1006-01C Connecting rod bearing radial play mm 0.064 to 0.126 0.064 to 0.126