11 21 500 Replacing crankshaft (N47 D20 O1) as from 6/2013

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. See 11 00 MOUNTING ENGINE ON ASSEMBLY STAND (N47 D20 O1) .
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. See CRANKSHAFT AND BEARINGS (N47)

If the permitted side clearance is exceeded:

Check crankshaft and guide bearing shells.
Replace worn component.

Fig 1: Checking Crankshaft Side Clearance
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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 With Suitable Tool

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Turn crankshaft (1) to top dead center until the counterbalance shafts (2 and 3) are facing down with the locating bore (see arrow).

Fig 3: Identifying Crankshaft & Counterbalance Shafts

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Turn crankshaft until special tool 2 288 054 engages in the counterbalance shaft.

See arrows.

Fig 4: Turning Crankshaft

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Secure special tool 2 288 054 to the crankshaft with screws (1).

Fig 5: Securing Special Tool 2 288 054 To Crankshaft With Screws

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Slacken nut (1).

Tightening torque: 11 27 2AZ .

Undo screws (2 and 3)

Tightening torque: 11 27 1AZ

Fig 6: Identifying Slacken Nut And 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: Identifying Intermediate Gearwheel

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Screw special tool 11 8 870 into counterbalance shaft gear, thereby releasing counterbalance shafts from the 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.

Release needle bearing (1) in direction of arrow.

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

Fig 9: Releasing Needle Bearing

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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: Graphic at bearing seat number 5.

Fig 10: Identifying Bearing Cap Marks 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: Identifying Main Bearing Caps

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Oil bearing shell.

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.

Fig 12: Identifying Bearing Caps

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

Align bearing cap exactly.

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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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).

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

Fig 14: Identifying Marks On Drive Gears And Intermediate Gearwheel

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Installation note:

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

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: For better graphic without crankshaft.

Fig 15: Fitting Right Counterbalance Shaft Gear

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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: For better graphic without crankshaft.

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

Fig 16: Fitting Left Counterbalance Shaft Gear

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

NOTE: For better graphic without crankshaft.

Fig 17: Inserting Counterbalance Shafts

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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 18: Inserting Counterbalance Shaft Into Gear

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

NOTE: For better graphic without crankshaft.

Fig 19: Positioning Counterbalance Shaft Of 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 20: Inserting Counterbalance Shaft Into Gear

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

NOTE: For better graphic without crankshaft.

Fig 21: Positioning Counterbalance Shaft Of 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.

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 .

Fig 22: Identifying Screw Both Bolts Into Counterbalance Shafts

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Prepare special tool 2 288 054 .

Fig 23: Identifying Special Tool (2 288 054)

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Adjust crankshaft (1) in first cylinder top dead center.

Turn counterbalance shafts (2 and 3) to installation position (see arrows).

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

Fig 24: Locating Counterbalance Shafts

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Position both counterbalance shafts.

Position special tool 2 288 054 so that there is no gap.

Fig 25: Positioning Special Tool So There Is No Gap

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Screw special tool 2 288 054 into the crankshaft with 20 Nm with screws (1).

The crankshaft and counterbalance shafts are now positioned.

Fig 26: Securing Special Tool (2 288 054) Into Crankshaft With 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 27: Identifying 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.

Install intermediate gearwheel.

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

Tightening torque: 11 27 1AZ .

Fig 28: Securing Bolt For Counterbalance Shafts Using Special Tool

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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 29: Identifying Marks On Drive Gears And Intermediate Gearwheel

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Tighten nut (1).

Tightening torque: 11 27 2AZ .

Fig 30: Identifying Nut And Screws

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Check Side clearance. See CRANKSHAFT AND BEARINGS (N47) .

Fig 31: Checking Crankshaft Side Clearance

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Assemble engine.