11 21 500 Replacing Crankshaft (N55)

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Special Tools Required:

IMPORTANT: Aluminum Screws/Bolts Are Permitted with and Without Color Coding (Blue).
Aluminum Screws/Bolts Must Be Replaced Each Time They Are Released .
for Reliable Identification:
Aluminum Screws/Bolts Are Not Magnetic .
Joining Torque and Angle of Rotation Must Be Observed Without Fail (Risk of Damage) .

Necessary Preliminary Tasks:

Remove ENGINE .
Mount Engine On ASSEMBLY STAND .
Remove VIBRATION DAMPER .
Remove OIL SUMP .
Remove OIL PUMP .
Remove TIMING CHAIN (UP TO MARCH 2012) .
Remove Oil Pump/Vacuum Pump CHAIN MODULE (FROM MARCH 2012) .
Remove CYLINDER HEAD .
Remove FLYWHEEL .
Remove All PISTONS .

Release Screws (1).

Tightening torque 11 13 5AZ .

Installation Note:

Replace Aluminum Screws.

Remove Oil Deflector with Integrated Intake Snorkel.

Fig 1: Removing Screws

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Release Aluminum Screws (1).

Release Aluminum Screws (2).

Installation Note:

Replace Aluminum Screws.

Fig 2: Identifying Aluminum Screws

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Release Aluminum Screws (1).

Installation Note:

Replace Aluminum Screws.

NOTE: Graphic Shows N52.

Fig 3: Identifying Aluminum Screw

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Release Screws (1).

Unfasten Screws (2).

Installation Note:

Replace Aluminum Screws.

Release Steel Screws (14 To 1) From Outside Inwards.

Remove Crankcase Lower Section Upwards.

Fig 4: Crankcase Steel Bolts Tightening/Loosening Sequence (N55)

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IMPORTANT: Remove Crankshaft with Aid of A Second Person.
Weight of Crankshaft Approx. 25 Kg.

Remove Crankshaft (1) Upward In Direction of Arrow.

Remove BEARING SHELLS (2) and Guide Bearing Shell (3), Replace If Necessary.

Fig 5: Installing Bearing Shells and Guide Bearing Shell

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Clean All Sealing Surfaces (1) with Special Tool 11 4 470 .

Fig 6: Identifying Sealing Surfaces

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Check Fitting Bushes for Damage and Secure Seating; Replace If Necessary.

Install All BEARING SHELLS .

Installation Note:

Oil All Bearing Points Adequately with Engine Oil.

Fig 7: Checking Bushes

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IMPORTANT: Insert Crankshaft with Aid of A Second Person.
Weight of Crankshaft Approx. 25 Kg.

Insert Crankshaft (1).

Fit Crankcase Lower Section (Watch Fitting Bushes).

Fig 8: Identifying Crankshaft

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Follow Tightening/Torque Sequence for The Steel Bolts (1 To 14).

Fig 9: Crankcase Steel Bolts Tightening/Loosening Sequence (N55)

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JOIN Steel Bolts (1).

Fig 10: Tightening Steel Bolts

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Mark Across All Steel Bolts (1) with A Colored Mark.

Fig 11: Placing Mark Across Steel Bolts

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Tighten All Steel Bolts with A Special Tool 00 9 120 .

Tightening torque 11 11 1AZ .

Installation Note:

All Steel Bolts Must Be Positioned The Same with Respect To The Colored Mark After Being Fastened (See Fig 9)

Fig 12: Tightening Engine Block Steel Bolts Using Special Tool 00 9 120

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Installation Note:

Aluminum Bolts (1) and (2) Can Have A Blue Colored Mark.

Aluminum Screws/Bolts Are Not Magnetic .

Fig 13: Identifying Aluminum Bolts

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IMPORTANT: In The Case of Aluminum Screws, Joining Torque and Angle of Rotation Must Be Observed Without Fail.

Join All Aluminum Bolts (1) From Inside Toward The Outside.

NOTE:

Replace Screws.

Thread Repairs Exclusively with Al Helicoil.

Joining Torque and Angle of Rotation Must Be Observed Without Fail.

Tightening torque 11 11 2AZ .

Fig 14: Joining Aluminum Bolts

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Mark Across All Aluminum Bolts (1) with A Colored Mark.

Fig 15: Placing Mark Across Aluminum Bolts

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Tighten All Aluminum Bolts (1) Only with Special Tool 00 9 120 .

Tightening torque 11 11 3AZ .

Tightening torque 11 11 4AZ .

Installation Note:

All Aluminum Bolts Must Be Equally Positioned with Respect To The Colored Mark After Being Fastened.

Fig 16: Tightening Aluminum Bolts Using Special Tool 00 9 120

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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 with Knurled Screw (2) On Zero.

Fig 17: Positioning Special Tools

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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

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Turn Crankshaft (1) Via The Central Bolt with Special Tool 00 2 010 To Determine The COEFFICIENT OF FRICTION .

Fig 19: Determining Coefficient of Friction By Turning Crankshaft Central Bolt Using Special Tool 00 2 010

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Drive Both Injector Nozzles (1) On Left and Right On Crankcase Into The Bore Hole (See Arrow In Illustration) with Special Tool 11 9 360 .

Installation Note:

Replace Injector Nozzles (1).

Fig 20: Driving Injector Nozzle Into Bore Hole Using Special Tool 11 9 360

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Drive In Both Injector Nozzles (1) On Left and Right Into Crankcase with Special Tool 11 9 360 .

Fig 21: Driving Injector Nozzle Into Crankcase Using Special Tool 11 9 360

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Drive Injector Nozzle (1) All The Way In.

Fig 22: Driving Injector Nozzles All The Way In

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Installation Note:

Use PRIMER 1.3 AND LIQUID SEALING COMPOUND 1.4 .

Prepare Liquid Sealing Compound (2) In Syringe (3).

Screw On Nozzle (1) for Injecting Sealing Compound.

Fig 23: Identifying Nozzle, Syringe, Sealing Compound, and Loctite Primer

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Slowly Insert Liquid Sealing Compound (1) with Syringe and Special Tool 11 4 370 In Direction of Arrow.

Graphic Shows Engine N42.

Fig 24: Inserting Liquid Sealing Compound Using Syringe and Special Tool 11 4 370

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Replace CRANKSHAFT SEAL At Front.

Replace CRANKSHAFT RADIAL SEAL (Transmission Side).

Assemble Engine.