11 21 500 Replacing Crankshaft (N63)

Special Tools Required:

IMPORTANT: Weight of Crankshaft Is Approx. 20 Kg.
Risk of Injury From Sharp Edge of Housing.

Necessary Preliminary Tasks:

Remove ENGINE .
MOUNT Engine On Assembly Stand.
Remove Cylinder Heads. See LEFT CYLINDER HEAD and RIGHT CYLINDER HEAD .
Remove HUB FOR VIBRATION DAMPER .
Remove LOWERING TIMING CASE COVER .
Remove Oil Pan. See LOWER OIL SUMP SECTION and UPPER OIL SUMP SECTION .
Remove OIL PUMP .
Remove PISTONS .
Remove FLYWHEEL .
Remove Radial Shaft Seals. See SEALING IN LOWERING TIMING CASE COVER and SEALING ON TRANSMISSION SIDE .
Remove TIMING CHAINS .

Installation Note:

Layout of Main Bearing Caps.

All Numbers Must Be Read From The Cylinder Bank (5 To 8) (See Arrows In Illustration).

Fig 1: Identifying Numerical Layout of Main Bearing Caps for Cylinders 5 Through 8

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Main Bearing Caps (1 To 5) Opposite The Output End On The Timing Chain Drive.

Fig 2: Identifying Number Markings On Main Bearing Caps 1 Through 5

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Release Oil Pump Spacer Bolts (1) with Special Tool 13 5 020 .

Fig 3: Releasing Oil Pump Spacer Bolts Using Special Tool 13 5 020

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Release Main Bearing Taper Screw Connection (1).

Release Oil Pump Spacer Pins (2).

Fig 4: Identifying Oil Pump Spacer Pins and Main Bearing Taper Screw

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Release All Threaded Support Sleeves (1).

Fig 5: Identifying Support Sleeves

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Release Collar Bolts (M8) In Sequence 10 To 1.

Fig 6: Main Bearing Cap Bolts Tightening/Loosening Sequence (N63)

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Release Collar Bolts (M11) In Sequence 10 To 1.

Remove Main Bearing Caps 1 To 5.

IMPORTANT: Remove Crankshaft with A 2Nd Person, Weight Approx. 25 Kg.

Lift Out Crankshaft and Set Down Safely (Secure Against Turning).

Fig 7: Main Bearing Cap Bolts Tightening/Loosening Sequence (N63)

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Release Screw for Oil Nozzle (1).

Tightening torque: 11 11 8 AZ .

Fig 8: Identifying Oil Nozzle Screw

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Installation Note:

Check Oil Nozzle (1) for Clear Passage with Compressed Air.

Observe Fastening On Oil Nozzle.

Fig 9: Identifying Oil Nozzle

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Installation Note:

Observe Fastening In Crankcase.

Fig 10: Identifying Fastener

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Replace CRANKSHAFT MAIN BEARING SHELLS .

Installation Note:

Observe Arrangement of Main Bearing Caps.

All Numbers Must Be Read From The Cylinder Bank (5 To 8) (See Arrows In Illustration).

Fig 11: Identifying Numerical Layout of Main Bearing Caps for Cylinders 5 Through 8

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Main Bearing Caps (1) Is Opposite The Output End On The Timing Chain Drive.

Turn Back All Threaded Support Sleeves Hand-Tight.

Installation Note:

Coat All Bearing Positions with Engine Oil.

IMPORTANT: Install Crankshaft with A 2Nd Person, Weight Approx. 25 Kg.

Install Crankshaft.

Fit Bearing Caps (1 To 5).

Fig 12: Identifying Number Markings On Main Bearing Caps 1 Through 5

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Set Down Bearing Caps Positioned From 1 To 5.

Insert All Collar Bolts (M11) Hand-Tight.

Secure Collar Bolts (M11) In Sequence (1 To 10).

Fig 13: Main Bearing Cap Bolts Tightening/Loosening Sequence (N63)

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Installation Note:

for A Better Overview of The Screw Connection Quality, Mark The Head of All Collar Bolts After Joining with A Line (1) Using An Oil-Proof Marker Pen.

Check Angle Tightening.

Fig 14: Placing Mark On Heads of Collar Bolts

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Secure Collar Bolt (1) with Special Tool 00 9 120 .

Tightening torque: 11 11 1AZ .

Fig 15: Tightening Collar Bolts of Main Bearing Caps Using Special Tool 00 9 120

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Insert All Collar Bolts (M8) Hand-Tight.

Secure Collar Bolts (M8) In Sequence (1 To 10).

Fig 16: Main Bearing Cap Bolts Tightening/Loosening Sequence (N63O1)

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Installation Note:

for A Better Overview of The Screw Connection Quality, Mark The Head of All Collar Bolts After Joining with A Line (1) Using An Oil-Proof Marker Pen.

Check Angle Tightening.

Fig 17: Placing Mark On Heads of Collar Bolts

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Secure Collar Bolt (1) with Special Tool 00 9 120 .

Fig 18: Securing Collar Bolt Using Special Tool 00 9 120

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Secure All Threaded Support Sleeves (1) with Special Tool 11 4 350 .

Tightening torque: 11 11 3 AZ .

Fig 19: Securing Threaded Support Sleeves Using Special Tool 11 4 350

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Secure Main Bearing Taper Screw Connection (1).

Tightening torque: 11 11 4 AZ .

Secure Oil Pump Spacer Pins (2).

Tightening torque: 11 11 5 AZ .

Fig 20: Identifying Oil Pump Spacer Pins and Main Bearing Taper Screw

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Check Crankshaft COEFFICIENT OF FRICTION .

Determine Crankshaft Breakaway Torque with Special Tool 00 2 010 .

Rotate Crankshaft At Central Bolt Using Special Tool 00 2 010 .

If The Breakaway Torque Is Too High, It Will Be Necessary To Correct The BEARING CLEARANCE .

Fig 21: Determining Crankshaft Breakaway Torque By Turning Crankshaft Central Bolt Using Special Tool 00 2 010

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Secure Special Tool 11 6 252 To Crankcase with Magnetic Base.

Slide Crankshaft In Direction of Arrow Forwards As Far As It Will Go.

Set Special Tool 11 6 251 To Zero.

Slide Crankshaft (1) In Direction of Arrow Towards Rear and Determine Value.

Check AXIAL PLAY .

Fig 22: Securing/Positioning Special Tools

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Assemble Engine.