11 21 505 Sealing the crankcase's lower part (N52K)

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IMPORTANT: Aluminium-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.
.
Remove CLUTCH (if fitted). See 21 21 500 REMOVING AND INSTALLING/REPLACING CLUTCH (SAC) (X3)
Remove left and right engine support arm
Remove OIL SUMP .

Release screws (1).

Pull out oil pump intake pipe (2).

Tightening torque: 11 13

Fig 1: Removing Intake Pipe

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Release screws (1).

Tightening torque, see 11 13 6AZ in 11 13 OIL PAN .

Installation:

Replace aluminum screws

Remove oil deflector (2).

Fig 2: Identifying Screws And Oil Deflector

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Secure oil pump sprocket with steel pin 6.0 mm (3) to oil pump.

IMPORTANT: Release central bolt (2) only together with steel pin 6.0 mm (3).
Do not remove sprocket.

Release central bolt (2).

Tightening torque, see 11 41 6AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Fig 3: Identifying Oil Deflector And Screws

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Unfasten screws (2).

Tightening torque: see 11 41 5AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Installation:

Replace aluminum screws

Fig 4: Identifying Bolt And 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 Oil Pump Triangular Drive Screw

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Version 1

IMPORTANT: Observe different screw lengths.

Release screws (1).

Tightening torque, see 11 41 2AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Tightening torque, see 11 41 3AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Installation:

Replace aluminum screws

Fig 7: Identifying Screws

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Version 2

IMPORTANT: Observe different screw lengths.
Release oil pump screws (1).
Tightening torque, see 11 41 2AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .
Installation:

Replace aluminum screws

Fig 8: Identifying 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: Pulling Drive Gear

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Installation

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 Spacer Bushings And Oil Pump

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NOTE: The special tool bore for the TDC position is located on the inlet side underneath the starter motor.

Rotate engine at central bolt and secure flywheel in position with special tool 11 0 300.

Fig 11: Securing Crankshaft

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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)

Fig 12: Securing Flywheel Using Special Tool 11 9 260/11 9 266

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Automatic transmission

Release flywheel bolts (1).

Release special tool (2).

Remove flywheel (3).

Fig 13: Identifying Flywheel With Bolts And Special Tool

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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: Removing Flywheel Bolts Using Special Tool 11 4 180

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Fig 15: Identifying Crankshaft Bolt Mounting Area

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

Fig 16: Crankcase Bolts Tightening/Loosening Sequence

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Release crankcase bolts M10 in sequence 14 to 1.

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 Crankshaft (Lower Section And Upper Section) Using Tool

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IMPORTANT: Timing chain is pre-tensioned.
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: Catching Escaping Engine Oil Using Cloth

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

Fig 20: Protecting Crankcase Against Sealant Residues Using Cloth

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

Remove injector nozzles (2) for liquid sealing compound on left and right.

Installation:

Replace injector nozzles (2).

Clean all threads with compressed air.

Fig 21: Identifying Injector Nozzle And Sealant Residue

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

Screw in all M10 crankcase bolts.

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

Fig 22: Screwing In All M10 Crankcase Bolts

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

Fig 23: Identify M10 Crankcase Bolts

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Fig 24: Crankcase Bolts Tightening/Loosening 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, see 11 11 CRANKCASE

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, see 11 11 CRANKCASE

Tighten screw (1) for oil pump triangular drive with special tool 11 8 640 .

NOTE: Replace screw.

Tightening torque, see 11 41 4 AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Fig 26: Identifying Oil Pump Triangular Drive Mounting Screw

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Tighten screw plug on front of crankcase.

Tightening torque, see 11 11 8 AZ in 11 11 CRANKCASE .

Installation:

Replace sealing ring.

Fig 27: Identifying Screw Plug On Crankcase

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

Fig 28: Identifying 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 Using Special Tool 11 8 220 On Crankshaft

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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 Parallel Up Against Crankcase

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

Fig 31: Screwing Special Tool 11 9 182 With Screws (Special Tool 11 9 184 ) To Crankshaft

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Installation:

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 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.

Fig 33: Pulling Radial Shaft Seal Using Special Tool 11 9 181/11 9 185/11 9 183

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

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

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Installation:

Clean sealing surface (1) and degrease thoroughly in area of housing partition.

Apply a light coat of oil to running surface (2) of radial seal.

NOTE: Graphic N42.

Fig 35: Identifying Sealing Surface And Running Surface For Crankshaft Radial Seal

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

Fig 36: Pushing Radial Shaft Seal (11 9 235) On Special Tool

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

Fig 37: Mounting Special Tool 11 9 235 With Special Tool 11 9 234 On Crankshaft

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Screw special tool 11 9 235 with special tool 11 9 234 on crankshaft.

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: Identifying Radial Shaft Seal , Housing Partition And Groove

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Draw in radial seal with special tool 11 9 231 in conjunction with special tool 11 9 233 until flush.

Fig 39: Inserting Radial Seal With Special Tool 11 9 231 And 11 9 233

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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: Inserting 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:

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.

Fig 42: Identifying Injector With Primer Bottle

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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.

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

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 44: Coating Surface Of Sealing Compound In Both Grooves Using Loctite Primer

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Stop (seal off) escaping liquid gasket with primer 1.3.

Fig 45: Sealing Escaping Liquid Gasket With Primer

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Assemble engine.