11 21 500 Replacing the crankshaft (N47)

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Special tools required:

IMPORTANT: Replace main and connecting rod bolts.
There must be no oil in the blind holes (risk of cracking) .
Do not wash off bolt coating.
Incorrect assembly of the bearing caps will result in damage to the crankcase.
It is necessary to remove the counterbalance shafts (AGW) in order to remove the crankshaft.
To properly adjust the counterbalance shafts, a new, coated intermediate gear must always be fitted.

Necessary preliminary tasks:

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove CYLINDER HEAD .
Remove COOLANT PUMP .
Remove OIL PUMP .
Remove END COVER at rear.
Remove both TIMING CHAINS .
REMOVE ALL PISTONS .

Check crankshaft side clearance.

Fit special tool 11 6 250 .

SIDE CLEARANCE .

If the permitted side clearance is exceeded:

Check crankshaft and guide bearing shells.
Replace worn component.

Fig 1: Checking Crankshaft And Guide Bearing Shells
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Remove sealing caps (1) with a suitable tool (2).

Installation note:

Replace sealing cap with O-ring.

Fig 2: Removing Sealing Caps

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Turn crankshaft until special tool 11 8 750 engages in left counterbalance shaft (1) (see arrow).

NOTE: Figure shows crankshaft removed.

Fig 3: Turning Crankshaft Until Special Tool (11 8 750) In Left Counterbalance Shaft

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Turn crankshaft until special tool 11 8 750 engages in right counterbalance shaft (1).

See arrow.

NOTE: Graphic shows crankshaft removed.

Fig 4: Turning Crankshaft Until Special Tool (11 8 750) In Right Counterbalance Shaft

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NOTE: Picture shows N47.

Special tool 11 8 750 can only be attached to the coolant pump on the crankcase using a bolt (1).

Fig 5: Attaching Special Tool (11 8 750) To Coolant Pump On Crankcase Using Bolt

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Slacken nut (1).

Tightening torque: 11 27 2AZ .

Undo screws (2 and 3)

Tightening torque: 11 27 1AZ

Fig 6: Screws

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Remove nut from intermediate gearwheel (1).

Remove intermediate gearwheel (1).

NOTE: The gear is pressed onto the counterbalance shaft with a taper and can only be released with special tool 11 8 870 .
Once the gear has been released from the counterbalance shaft, special tool 11 8 870 can be unscrewed again by hand.

Fig 7: Removing Intermediate Gearwheel

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Screw special tool 11 8 870 into counterbalance shaft gear and release counterbalance shafts from gears.

IMPORTANT: Risk of damage! on crankcase.
Use special tool 00 2 300 to move engine to vertical position.

Remove counterbalance shaft (1) in upward direction of arrow from crankcase (2).

NOTE: Shown with crankshaft removed for clearer illustration.

Fig 8: Removing Counterbalance Shaft

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IMPORTANT: Danger of mixing up needle bearings.
Needle bearings have different diameters.

Fig 9: Releasing Needle Bearing

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Release needle bearing (1) in direction of arrow.

Remove released needle bearing (1) from counterbalance shaft (2) in direction of arrow.

Check counterbalance shaft (2) for wear at the bearing position and replace if necessary.

NOTE: Bearing caps (1) 1...5 are marked on the exhaust side.
Bearing cap 3 is installed as a thrust bearing.

NOTE: Illustration shows bearing seat number 5.

Fig 10: Bearing Caps 5 Mark On Exhaust Side

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Release main bearing screw connection of main bearing cap (1).

Remove main bearing cap 1...5.

IMPORTANT: With the assistance of a second person, remove crankshaft and carefully place to one side.
Pay attention to oil hole in bearing shell.
Pay attention to installation position of CRANKSHAFT MAIN BEARING SHELLS .

Fig 11: Main Bearing Cap

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Coat bearing shells with oil.

Install crankshaft.

Fit bearing caps 1 to 5 so that the ID codes always point to the exhaust side.

Both locating grooves of bearing shells in crankcase and on bearing cap must be mounted on one side.

IMPORTANT: Do not fit bearing cap in incorrect position.
Risk of damage to moulding on crankcase.

Align bearing cap exactly.

Fig 12: Bearing Caps

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Fit main bearing bolts.

Tighten main bearing bolts in sequence (1 to 10) (observe tightening specifications).

Tightening torque: 11 11 1AZ .

Fig 13: Main Bearing Cap Bolts Tightening/Loosening Sequence (N47 D20 O1)

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IMPORTANT: The crankshaft must be fixed in the BDC position of cylinder No. 1 in order to adjust the counterbalance shafts.

Position special tool 11 8 791 on crankcase and secure with special tool 11 8 793 .

Fig 14: Positioning Special Tool (11 8 791) On Crankcase

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Secure crankshaft with knurled screw 11 8 792 on special tool 11 8 791 .

Use special tool 00 2 300 to move engine to vertical position.

Fig 15: Securing Crankshaft With Knurled Screw (11 8 792) On Special Tool (11 8 791)

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Schematic representation of the differential bevel and intermediate gears.

IMPORTANT: To adjust the counterbalance shafts, it is essential to fit a new coated intermediate gearwheel (2).

Fig 16: Marks On Drive Gears And Intermediate Gearwheel

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All marks on the drive gears (1 and 3) and intermediate gearwheel (2) must point vertically to the oil sump sealing surface (upwards).

Installation note:

To facilitate installation of counterbalance shafts, rotate engine with special tool 00 2 300 to a convenient working position.

Fig 17: Fitting Right Counterbalance Shaft Gear

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Fit gear (1) for right counterbalance shaft in direction of arrow.

Marks on drive gear counterbalance shaft (1) must point vertically to oil sump sealing surface (upwards).

NOTE: Shown with crankshaft removed for clearer illustration.

IMPORTANT: Risk of mixing up gears.
Pay attention to inclination of tooth flanks.

Fit gear (1) for left counterbalance shaft in direction of arrow.

Marking on drive gear (1) must point vertically to oil pan sealing surface (upwards).

NOTE: Shown with crankshaft removed for clearer illustration.

Fig 18: Fitting Left Counterbalance Shaft Gear

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IMPORTANT: Risk of mixing up gears.
Pay attention to inclination of tooth flanks.

Insert counterbalance shafts (1) in direction of arrow in crankcase (2).

NOTE: Shown with crankshaft removed for clearer illustration.

Fig 19: Inserting Counterbalance Shafts In Crankcase

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IMPORTANT: Do not drop counterbalance shafts into the bearing positions.

Insert special tool 64 1 020 or a suitable tool through the gear into the counterbalance shaft.

Carefully insert counterbalance shaft (1) into gear in direction of arrow.

Fig 20: Inserting Special Tool (64 1 020) And Gear Into Counterbalance Shaft

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Position counterbalance shaft (1) in direction of arrow in gear (2).

NOTE: Shown with crankshaft removed for clearer illustration.

Fig 21: Positioning Counterbalance Shaft In Gear

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IMPORTANT: Do not drop counterbalance shafts into the bearing positions.

Insert special tool 64 1 020 or a suitable tool through the gear into the counterbalance shaft.

Carefully insert counterbalance shaft (1) into gear in direction of arrow.

Fig 22: Inserting Special Tool (64 1 020) And Gear Into Counterbalance Shaft

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Position counterbalance shaft (1) in direction of arrow in gear (2).

NOTE: Shown with crankshaft removed for clearer illustration.

Fig 23: Positioning Counterbalance Shaft In Gear

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Screw both bolts (1) into the counterbalance shafts on the left and right.

Do not tighten both bolts otherwise the counterbalance shafts may jam and it will no longer be possible to position them in the next operation.

Fig 24: Counterbalance Shafts Bolts

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Position both counterbalance shafts.

The balance weights of the counterbalance shafts must point to the oil sump. For this purpose, the engine must be moved into the normal position with special tool 00 2 300 .

Both counterbalance shafts together with the balance weights must now face downwards towards the oil sump.

Secure special tool 11 8 750 to the crankcase using the screws (1) for the coolant pump.

Special tool 11 8 750 can only be attached to the coolant pump on the crankcase using a bolt (1).

NOTE: Picture shows N47.

Fig 25: Securing Special Tool (11 8 750) To Crankcase Using Coolant Pump Screws

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Schematic representation of the differential bevel and intermediate gears.

All marks on the drive gears (1 and 3) and intermediate gearwheel (2) must point vertically to the oil sump sealing surface (upwards).

Fig 26: Marks On Drive Gears And Intermediate Gearwheel

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Installation note:

The gear must be loose on the right-hand counterbalance shaft otherwise it will not be possible to install the intermediate gearwheel.

Install new intermediate gearwheel with coating.

Fig 27: Screws

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Install intermediate gearwheel.

Secure bolt for counterbalance shafts (2 and 3) using special tool 00 9 120 .

Tightening torque: 11 27 1AZ .

IMPORTANT: Before the intermediate gear (2) is secured, the intermediate gear (2) must be pressed hand-tight onto the gearing of the crankshaft (4) and counterbalance shaft (3) until zero-lash is achieved in both gears.

Fig 28: Marks On Drive Gears And Intermediate Gearwheel

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Tighten nut (1).

Tightening torque: 11 27 2AZ .

Fig 29: Screws

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Check SIDE CLEARANCE .

Fig 30: Checking Crankshaft And Guide Bearing Shells

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Assemble engine.