Sealing crankcase lower section (S55 engine)

Special tools required:

11 8 530
11 8 533
11 8 532
11 8 534
11 8 531
11 8 535
11 8 537
2 303 793
11 8 640
11 0 300
11 4 180
11 9 260
11 9 231
2 303 795
11 4 470
00 9 120
11 8 220
11 9 182
11 9 184
11 9 181
11 9 185
11 8 181
11 9 183
11 9 235
11 9 360
11 4 370

IMPORTANT: Aluminium-magnesium materials.
Aluminium screws/bolts must be replaced each time they are released .
For reliable identification:
Aluminium screws/bolts are not magnetic .
Risk of damage!
Jointing 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 .
MOUNT ENGINE ON ASSEMBLY STAND .
Remove both drive belts. Refer to REPLACING DRIVE BELT FOR ALTERNATOR and REPLACING DRIVE BELT FOR COOLANT PUMP .
Remove engine support arm on left and right. Refer to REPLACING LEFT ENGINE SUPPORT ARM and REPLACING RIGHT ENGINE SUPPORT ARM .
Remove OIL SUMP .

Removing sealing cap:

Prepare special tool 11 8 530.

Remove special tool 11 8 533 from special tool 11 8 532.

Install special tool 11 8 534.

Special tool 11 8 536 is not required.

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Attach special tool 11 8 531 to long special tool 11 8 535.

Short special tool 11 8 535 (short); a 6 mm thick M10 washer must be placed underneath between crankcase and special tool 11 8 531.

NOTE: For purposes of clarity, illustrations show alternator and power steering pump removed.

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Special tool 11 8 537 must be positioned manually on sealing cap.

Screw in special tool 11 8 534.

NOTE: The sealing cap is pressed out diagonally during this work step

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Drive out sealing cap (1) with a suitable punch (2) in direction of arrow.

NOTE: The sealing cap is driven out diagonally during this operation.

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Release screw (1).

Oil suction pipe must be detached to remove exhaust turbocharger return line for cylinders 4 to 6.

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Release screws (1).

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Release screw (1) by 180°.

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Release screw (1).

Remove oil suction pump rearwards.

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Remove bolt (1).

Release aluminium screws (2).

Installation note:

Replace aluminium screws .

Remove intake pipe with oil deflector.

Installation note:

Replace O-ring.

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IMPORTANT: Before releasing the central bolt on the oil pump, the hydraulic chain tensioner must be drained.

Carefully press tensioning rail (1) with a suitable screwdriver (2) in direction of arrow.

As the oil pressure in the chain tensioner can only be drained pulsating, the tensioning rail (1) must be pressed several times.

Relieve the tension using a suitable lock pin on the chain drive.

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Press the tensioning rail (1) and hold down.

Chain tensioner piston with a suitable lock pin (2) with a diameter of 2.5 to 3 mm.

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NOTE: Sprocket must be blocked in order to release central bolt (1).

Secure special tool 2 303 793 to crankcase.

Release oil pump central bolt (1).

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Release aluminium screws (1).

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Release aluminium screws (1).

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Detach sprocket (1) in direction of arrow.

NOTE: Do not remove sprocket (1).

Remove oil pump (2) in direction of arrow.

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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.

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Remove fastener (1) in direction of arrow.

Installation note:

Install fastener (1) with bore facing outwards.

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Release screw (1) and press the cable clip (2) to one side.

Rotate crankshaft at central bolt into TDC setting.

Slide in special tool 11 0 300 into dowel hole and secure crankshaft.

IMPORTANT: If the flywheel is secured in the correct dowel hole with special tool 11 0 300, the engine can no longer be moved at the central bolt.

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IMPORTANT: To loosen the flywheel bolts with special tools 11 4 180 and 11 9 260

Secure flywheel with special tool 11 9 260.

Remove CLUTCH if necessary.

Release bolts with special tool 11 4 180.

Remove flywheel.

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Release screws on vibration damper.

Remove vibration damper.

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Release screws (1).

Place coolant pump and holder to one side.

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Release screws (1).

Tightening torque 11 42 7AZ .

Release oil return line (2) in direction of arrow.

Installation note:

Replace O-ring.

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Release screws (1).

Tightening torque 11 42 7AZ .

Remove oil return pipe (3) in direction of arrow.

Installation note:

Replace O-ring.

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Release all crankcase bolts (1) along line (2).

Illustration shows N52.

Fig 1: Crankcase Bolts Loosening Sequence

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Release crankcase bolts M10 in sequence 14 to 1.

Illustration shows N52

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) .

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Pull off crankshaft seal (1) in direction of arrow.

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Installation note:

Changed crankshaft seal installation with special tools 11 9 231 and 2 303 795

Pull crankshaft seal (1) off forwards.

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IMPORTANT: Protect crankcase against sealant residues with a cloth (1).

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Remove sealing compound residues (1) with special tool 11 4 470.

Remove injector nozzles for liquid sealing compound on left and right.

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Installation note:

Replace injector nozzles for liquid sealing compound.

Clean all threads with compressed air.

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Installation:

Position crankcase lower section (1) on crankcase upper section.

Screw in all M10 crankcase bolts.

Joint all M10 crankcase bolts (1) 20 NM from inside outwards.

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Identify all M10 crankcase bolts with a colored marking (1) for checking.

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Fig 2: Crankcase Bolts M10 Tightening Sequence

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Secure crankcase bolts M10 in sequence 1 to 14 with special tool 00 9 120.

Tightening torque: 11 11 1AZ .

Illustration shows N52.

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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 7AZ .

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Tighten screw plug on front of crankcase.

Tightening torque: 11 11 7 AZ .

Installation note:

Replace sealing ring.

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Prepare radial shaft seal (1) on special tool 11 8 220.

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Position radial shaft seal (1) with special tool 11 8 220 on crankshaft.

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Brush radial shaft seal (1) over special tool 11 8 220.

Move radial shaft seal (1) parallel up against the crankcase.

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Screw special tool 11 9 182 with screws (special tool 11 9 184) 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.

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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.

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Screw on radial shaft seal with special tool 11 9 183 to limit position.

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Fasten flywheel in sequence 1 to 6.

Tightening torque: 11 22 1AZ / 2AZ .

Fig 3: Flywheel Screws Tightening Sequence

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Push radial shaft seal (1) 11 9 235 carefully in direction of arrow on the special tool.

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Remove support ring (1).

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IMPORTANT: Special tool 11 9 235 can only be fastened with
2 opposite bolts.
Determine hole pattern on special tool.

Fasten special tool 11 9 235 onto crankshaft by 2 screws (1).

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Position radial shaft seal (1) on crankcase in direction of arrow using special tool 11 9 235.

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Insert radial shaft seal flush into crankcase with special tool 11 9 231 and 2 303 795.

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Drive both injector nozzles (1) on left and right with special tool 11 9 360 into crankcase up to stop.

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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.

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Installation note:

Use PRIMER 1.3 AND LIQUID SEAL 1.4 .

Prepare liquid sealing compound (1) in special tool 11 4 370.

Injector nozzles for injecting sealing compound are not required.

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Slowly insert liquid sealing compound (1) with special tool 11 4 370 in direction of arrow.

Liquid sealing compound must emerge at radial shaft seals at front and rear.

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Stop (seal off) escaping liquid sealing compound with primer 1.3.

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Installation note:

Pay attention to dowel pin.

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Installation note:

Ensure installed position of magnet wheel is correct.

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Fasten screws in sequence 1 to 6.

Tightening torque: 11 22 1AZ / 2AZ .

Fig 4: Flywheel Screws Tightening Sequence

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Stop (seal off) escaping liquid sealing compound with primer 1.3.

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Attach vibration damper.

Fasten screws on vibration damper in sequence 1 to 8.

Tightening torque: 11 23 1AZ .

Fig 5: Vibration Damper Screws Tightening Sequence

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Assemble engine.

Install OIL PUMP .

Install OIL SUCTION PUMP .

Install SEALING CAP for vacuum pump.

Install SEALING CAP for oil pump drive chain tensioner.

Install OIL SUMP .

Install both drive belts. Refer to REPLACING DRIVE BELT FOR ALTERNATOR and REPLACING DRIVE BELT FOR COOLANT PUMP .

Install ENGINE .