11 21 500 Replacing crankshaft (N20)

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Special tools required:

Necessary preliminary tasks:

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove VIBRATION ABSORBER .
Remove oil sump. See OIL SUMP (RWD) or OIL SUMP (AWD) .
Remove OIL PUMP .
Remove timing CHAIN MODULE .
Remove CHAIN MODULE for oil pump.
Remove CYLINDER HEAD .
Remove FLYWHEEL .
Remove all PISTONS .

Release all screws (1).

Fig 1: Identifying Screws

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Undo screws (10 to 1) from the outside to the inside.

Fig 2: Crankcase Lower Section Bolts Tightening/Loosening Sequence (N20)

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Remove the crankcase lower section (1) in the direction of the arrow towards the top.

Fig 3: Removing Crankcase Lower Section

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IMPORTANT: Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 21 kg.

Remove crankshaft (1) upward in direction of arrow.

Remove and replace (if applicable) BEARING SHELLS and guide bearing shells.

Fig 4: Installing Bearing Shells And Guide Bearing Shell

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IMPORTANT: If the screw (1) is undone, the oil spray nozzle (2) must be readjusted.

Fig 5: Identifying Oil Spray Nozzle And Screw

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Installation note:

Setting the oil nozzle to the crankcase.

Place feeler gauge (2) between oil nozzle (1) and crankcase.

Fig 6: Placing Feeler Gauge Between Oil Nozzle And Crankcase

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Adjust feeler gauge to 0.40 mm.

Bring oil nozzle into contact with the feeler gauge by pressing lightly.

Tighten bolt (1).

Tightening torque. 11 11 3AZ .

Fig 7: Adjusting Feeler Gauge To 0.40mm And Tightening Bolt

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Clean all sealing surfaces (1) with special tool 11 4 470 .

Insert all CRANKSHAFT MAIN BEARINGS .

Installation note:

Remove residue of seals from the crankcase (2).

Check fitting bushes (1) for damage and replace if applicable.

Oil all bearing points adequately with engine oil.

Fig 8: Identifying Crankcase And Fitting Bushes

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IMPORTANT: Insert crankshaft with aid of a second person.
Weight of crankshaft approx. 21 kg.

Insert crankshaft (1).

Fig 9: Installing Bearing Shells And Guide Bearing Shell

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Installation note:

Check durability of sealing compound, do not use sealing compound that has expired.

Maximum processing time of the SEALING COMPOUND 2.2 10 minutes.

Fig 10: Identifying Sealing Bead

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Apply sealing compound in the stated areas with a width of 2.0 to 2.6 mm.

Fit crankcase lower section (watch fitting bushes).

Fig 11: Removing Crankcase Lower Section

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Please observe the tightening sequence of the screws (1 to 10).

Fig 12: Crankcase Lower Section Bolts Tightening/Loosening Sequence (N20)

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Join screws (1).

Fig 13: Joining Screws

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Mark all screws (1) with a crosswise colored mark.

Fig 14: Identifying Colored Mark Across Head Of Crankshaft Screw

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Re-tighten all screws using special tools 00 9 120 .

Tightening torque 11 11 1AZ .

Installation note:

After tightening all screws, the colored mark must be aligned in the same way.

Fig 15: Re-Tightening All Screws Using Special Tool (00 9 120)

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All screws (1) from the inside to the outside.

Tightening torque 11 11 2AZ .

Fig 16: Identifying Screws

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Fit special tool 11 6 252 with magnetic foot on special tool 11 4 440 .

Clamp special tool 11 6 251 on special tool 11 6 252 .

Position special tool 11 6 251 with button on the flat side of the crankshaft.

Press crankshaft (1) in direction of arrow up to stop.

Set dial gauge on zero with knurled screw (2).

Fig 17: Pressing Crankshaft Up To Stop And Setting Dial Gauge On Zero

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Press crankshaft (1) in direction of arrow from right to left up to stop.

Determine CRANKSHAFT AXIAL CLEARANCE .

Fig 18: Pressing Crankshaft Up To Stop

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Turn crankshaft (1) via the central bolt with special tool 00 2 010 to determine the COEFFICIENT OF FRICTION .

Graphic N55.

Fig 19: Turning Crankshaft Central Bolt Using Special Tool (00 2 010)

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Replace front CRANKSHAFT SEAL .

Replace CRANKSHAFT SEAL (transmission side).

Assemble engine.