11 21 505 Sealing Crankcase Lower Section (N55)

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Special Tools Required:

IMPORTANT: Aluminum-Magnesium Materials.
No Steel Screws/Bolts May Be Used Due To The Threat of Electrochemical Corrosion.
A Magnesium Crankcase Requires Aluminum Screws/Bolts Exclusively.
Aluminum Screws/Bolts Must Be Replaced Each Time They Are Released .
Aluminum Screws/Bolts Are Permitted with and Without Color Coding (Blue).
for Reliable Identification:
Aluminum Screws/Bolts Are Not Magnetic .
Risk of Damage!
Joining Torque and Angle of Rotation Must Be Observed Without Fail.

IMPORTANT: Changed Procedure.
It Is Not Necessary To Remove The Cylinder Head and The Crankshaft.

Necessary Preliminary Tasks:

Remove ENGINE .
MOUNTING ENGINE ON ASSEMBLY STAND .
Remove Clutch (If Fitted).
Remove Engine Support Arm On Left and Right.
Unscrew Oil Sump.

Release Screws (1).

Pull Out Oil Pump Intake Pipe (2).

Fig 1: Identifying Oil Pump Intake Pipe and Screws

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Release Screws (1).

Tightening torque: 11 13 5AZ .

Installation Note:

Replace Aluminum Screws.

Remove Oil Deflector (2).

Fig 2: Identifying Oil Deflector Screws

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Secure Oil Pump Sprocket with 6.0 Mm Dia. Steel Pin (3) To Oil Pump.

IMPORTANT: Release Central Bolt (2) Only Together with 6.0 Mm Dia. Steel Pin (3).
Do Not Remove Sprocket.

Release Central Bolt (2).

Tightening torque: 11 41 5AZ .

Fig 3: Releasing Central Bolt

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Unfasten Screws (2).

Tightening torque: 11 41 3AZ .

Installation Note:

Replace Aluminum Screws.

Fig 4: Identifying Screws

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Remove Screw Plug (1) From Crankcase At Front.

NOTE: Replace Gasket.

Fig 5: Identifying Screw Plug

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Release Screw (1) for Oil Pump Triangular Drive with Special Tool 11 8 640 .

NOTE: It Is Not Necessary To Remove The Triangular Drive.

Fig 6: Identifying Screw for Oil Pump Triangular Drive

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Version 1:

Attention!

Observe Different Screw Lengths.

Release Screws (1).

Tightening torque 11 41 2AZ .

Installation Note:

Replace Aluminum Screws.

Fig 7: Identifying Screws

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Version 2:

Attention!

Observe Different Screw Lengths.

Release Oil Pump Screws (1).

Tightening torque: 11 41 2AZ .

Installation Note:

Replace Aluminum Screws.

Fig 8: Identifying Oil Pump Screws

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Detach Sprocket (1) In Direction of Arrow.

NOTE: The Chain Tensioner Pushes The Timing Chain (3) of The Triangular Drive Upward.

Do Not Remove Camshaft Sprocket.

Remove Oil Pump (2) In Direction of Arrow.

Fig 9: Detaching Sprocket and Removing Oil Pump

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Installation Note:

Check Spacer Bushings (1) for Secure Seating and Damage; Replace If Necessary.

Align Twin Surface (3) On Oil Pump (2) To Sprocket Wheel.

Install Oil Pump (2).

Fig 10: Identifying Oil Pump, Twin Surface, and Spacer Bushings

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NOTE: The Special Dowel Hole for The TDC Setting Is Located On The Intake Side Underneath The Starter Motor.

Rotate Engine At Central Bolt and Secure Flywheel In Position with Special Tool 11 0 300 .

Fig 11: Securing Flywheel In Position Using Special Tool 11 0 300

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Secure Flywheel with Special Tool (1) 11 9 260 and Special Tool (2) 11 9 266.

Tightening torque

NOTE: Make Sure That The Special Tool (1) Completely Engages In The Flywheel Teeth (See Arrow In Illustration)

Fig 12: Securing Flywheel Using Special Tools 11 9 260 and 11 9 266

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Automatic Transmission

Release Flywheel Bolts (1).

Release Special Tool (2).

Remove Flywheel (3).

Fig 13: Identifying Flywheel, Special Tool, and Bolts

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Manual Gearbox

IMPORTANT: Position Crankshaft At TDC.

Remove Dual-Mass Flywheel.

Secure Flywheel with Special Tool 11 9 260 .

Remove VIBRATION DAMPER .

Release Flywheel Bolts with Special Tool 11 4 180 /

Fig 14: Securing Flywheel Using Special Tool 11 9 260 and Removing Bolts Using Special Tool 11 4 180

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Release All Crankcase Bolts (1) Along Line (2).

Fig 15: Identifying Crankcase Bolts

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Release Crankcase Bolts M10 In Sequence 14 To 1.

Fig 16: Crankcase Steel Bolts Tightening/Loosening Sequence (N55)

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Release Crankcase Lower Section (1) From Crankcase Upper Section (2) with Suitable Tool (3)

Remove Crankcase Lower Section (1) Upwards.

IMPORTANT: Do Not Rotate Crankshaft Without Crankcase Lower Section (1) (Risk of Damage) .

Fig 17: Removing Crankcase Lower Section From Crankcase Upper Section

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IMPORTANT: Timing Chain Is Preloaded.
Do Not Raise Crankshaft.

Carefully Remove Radial Shaft Seal (1).

Catch Escaping Engine Oil with A Cloth (2).

Fig 18: Removing Radial Shaft Seal

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Carefully Remove Radial Shaft Seal (1) Towards Front.

Catch Escaping Engine Oil with A Cloth (2).

Fig 19: Removing Radial Shaft Seal

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IMPORTANT: Protect Crankcase Against Sealant Residues with A Cloth (1).

Fig 20: Protecting Crankcase Against Sealant Residues with Cloth

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Remove Sealing Compound Residues (1) with Special Tool 11 4 470 .

Remove Injector Nozzles (2) for Liquid Sealing Compound On Left and Right.

Installation Note:

Replace Injector Nozzles (2).

Clean All Threads with Compressed Air.

Position Crankcase Lower Section (1) On Crankcase Upper Section.

Fig 21: Identifying Injector Nozzles and Crankcase Lower Section

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Screw In All M10 Crankcase Bolts.

Joint All M10 Crankcase Bolts (1) 20 NM From Inside Outwards.

Fig 22: Tightening Crankcase Bolts

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Identify All M10 Crankcase Bolts with A Colored Marking (1) for Checking.

Fig 23: Identifying Marking On M10 Crankcase Bolts

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Fig 24: Crankcase Steel Bolts Tightening/Loosening Sequence (N55)

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Secure Crankcase Bolts M10 In Sequence 1 To 14 with Special Tool 00 9 120 .

Tightening torque: 11 11 1AZ .

Fig 25: Identifying Crankcase Bolts

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Insert All Crankcase Bolts (1).

IMPORTANT: Observe Different Lengths and Sizes of The Bolts.

Tightening torque: 11 11 2, 3 AND 4AZ .

Tighten Screw (1) for Oil Pump Triangular Drive with Special Tool 11 8 640 .

NOTE: Replace Screw.

Tightening torque: 11 41 4 AZ .

Fig 26: Identifying Screw for Oil Pump Triangular Drive

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Tighten Screw Plug On Front of Crankcase.

Tightening torque: 11 11 9 .

Installation Note:

Replace Sealing Ring.

Fig 27: Identifying Screw Plug

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Prepare Radial Shaft Seal (1) On Special Tool 11 8 220 .

Fig 28: Preparing Radial Shaft Seal On Special Tool 11 8 220

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Position Radial Shaft Seal (1) with Special Tool 11 8 220 On The Crankshaft.

Fig 29: Positioning Radial Shaft Seal On Crankshaft Using Special Tool 11 8 220

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Brush Radial Shaft Seal (1) Over The Special Tool 11 8 220 .

Move Radial Shaft Seal (1) Parallel Up Against The Crankcase.

Fig 30: Moving Radial Shaft Seal Against Crankcase

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Screw Special Tool 11 9 182 To Crankshaft with Screws (Special Tool 11 9 184 ).

Fig 31: Installing Special Tools To Crankshaft

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Installation Note:

Prepare Special Tool 11 9 181 for Installation. Connect Special Tool 11 9 185 Onto Special Tool 11 8 181 .

Fig 32: Connecting Special Tool 11 9 185 Onto Special Tool 11 9 181

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Pull On Radial Shaft Seal with Special Tool 11 9 181 and 11 9 185 In Combination with Special Tool 11 9 183 .

Fig 33: Pulling On Radial Shaft Seal Using Special Tools 11 9 181, 11 9 185, and 11 9 183

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Screw On Radial Shaft Seal with Special Tool 11 9 183 To Limit Position.

Fig 34: Installing Radial Shaft Seal Using Special Tool 11 9 183

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Installation Note:

Clean Sealing Surface (1) and Degrease Thoroughly In Area of Housing Partition.

Apply A Light Coat of Oil To Tread (2) of Radial Seal.

NOTE: Graphic Shows Engine N42.

Fig 35: Identifying Running Surface and Sealing Surface

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Push Radial Shaft Seal (1) 11 9 235 Carefully In Direction of Arrow On The Special Tool.

Fig 36: Pushing Radial Shaft Seal Onto Special Tool 11 9 235

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IMPORTANT: 11 9 235 Special Tool Can Only Be Fastened with 2 Opposite Bolts.
Determine Hole Pattern On Special Tool.

Screw Special Tool 11 9 235 with Special Tool 11 9 234 On Crankshaft.

Fig 37: Installing Special Tools On Crankshaft

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Align Groove (2) of Radial Shaft Seal (1) Centered To The Housing Partition (3.

IMPORTANT: After Installation, The Grooves Must Be Filled with Sealing Compound.

Fig 38: Aligning Groove of Radial Shaft Seal Centered To Housing Partition

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Draw In Radial Shaft Seal with Special Tool 11 9 231 In Conjunction with Special Tool 11 9 233 Until Flush.

Fig 39: Identifying Special Tools On Radial Shaft Seal

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

Fig 40: Driving-In Injector Nozzles Using Special Tool 11 9 360

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After Fitting Both Sealing Rings, Check Both Sealing Ducts for Clearance.

Blow Compressed Air (1) At Max. 6 Bar Into Injector Nozzle (2).

Compressed Air Must Emerge At Both Sealing Rings On Left and Right From The Outlet Bores.

IMPORTANT: If The Compressed Air Does Not Flow Out of All Ducts. The Crankcase Must Again Be Taken Apart and Cleaned.

Fig 41: Blowing Compressed Air Into Injector Nozzle

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Installation Note:

Use PRIMER 1.3 AND LIQUID SEALING 1.4 .

Prepare Liquid Sealing Compound (1) In Syringe (3).

Injector Nozzles for Injecting Sealing Compound Are Not Required.

Take Note of The Expiry Date!

Fig 42: 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.

Liquid Sealing Compound Must Emerge At Radial Shaft Seals At Front and Rear.

Fig 43: Inserting Liquid Sealing Compound Using Syringe and Special Tool 11 4 370

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Stop (Seal Off) Escaping Liquid Sealing Compound with Primer 1.3.

Fig 44: Sealing with Primer

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Stop (Seal Off) Escaping Liquid Sealing Compound with Primer 1.3.

Fig 45: Inserting Brush Into Grooves On Crankshaft Seal

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Assemble Engine.