11 21 500 Replacing crankshaft (N55)

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Special tools required:

IMPORTANT: Aluminium screws/bolts are permitted with and without color coding (blue).
Aluminium screws/bolts must be replaced each time they are released .
For reliable identification:
Aluminium screws/bolts are not magnetic .
Jointing torque and angle of rotation must be observed without fail (risk of damage) .

Necessary preliminary work:

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove VIBRATION DAMPER .
Remove oil sump. See REMOVING OIL SUMP (RWD) or REMOVING OIL SUMP (AWD) .
Remove OIL PUMP .
Remove timing CHAIN MODULE .
Remove oil pump/vacuum pump CHAIN MODULE .
Remove CYLINDER HEAD .
Remove FLYWHEEL .
Remove all PISTONS .

Release screws (1).

Tightening torque 11 13 5AZ .

Installation note:

Replace aluminium screws.

Remove oil deflector with integrated intake snorkel.

Fig 1: Removing Oil Deflector

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Release aluminium screws (1).

Release aluminium screws (2).

Installation note:

Replace aluminium screws.

Fig 2: Identifying Aluminium Screws

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Release aluminium screws (1).

Installation note:

Replace aluminium screws.

NOTE: Graphic shows N52.

Fig 3: Identifying Aluminium Screws

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Release screws (1).

Unfasten screws (2).

Installation note:

Replace aluminium screws.

Release steel screws (14 to 1) from outside inwards.

Remove crankcase lower section upwards.

Fig 4: Crankshaft Bolts Tightening/Loosening Sequence (N55)

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IMPORTANT: Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 25 kg.

Remove crankshaft (1) upward in direction of arrow.

Remove BEARING SHELLS (2) and guide bearing shell (3), replace if necessary.

Fig 5: Installing Bearing Shells And Guide Bearing Shell

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Clean all sealing surfaces (1) with special tool 11 4 470 .

Fig 6: Identifying Sealing Surfaces

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Check fitting bushes for damage and secure seating; replace if necessary.

Install all BEARING SHELLS .

Installation note:

Oil all bearing points adequately with engine oil.

Fig 7: Checking Fitting Bushes

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IMPORTANT: Insert crankshaft with aid of a second person.
Weight of crankshaft approx. 25 kg.

Insert crankshaft (1).

Fit crankcase lower section (watch fitting bushes).

Fig 8: Inserting Crankshaft

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Follow tightening/torque sequence for the steel bolts (1 to 14).

Fig 9: Crankshaft Bolts Tightening/Loosening Sequence (N55)

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JOIN steel bolts (1).

Fig 10: Tightening Steel Bolts To Jointing Torque Specification

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Mark across all steel bolts (1) with a colored mark.

Fig 11: Identifying Mark Across Steel Bolt Head

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Tighten all steel bolts with a special tool 00 9 120 .

Tightening torque 11 11 1AZ .

Installation note:

All steel bolts must be positioned the same with respect to the colored mark after being fastened (see Fig 9).

Fig 12: Tightening Steel Bolts

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Installation note:

Aluminium bolts (1) and (2) can have a blue colored mark.

Aluminium screws/bolts are not magnetic .

Fig 13: Identifying Aluminium Bolts

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IMPORTANT: In the case of aluminium screws, jointing torque and angle of rotation must be observed without fail.

JOIN all aluminium bolts (1) from inside toward the outside.

Tightening torque 11 11 2AZ .

Fig 14: Tightening Aluminium Bolts To Jointing Torque Specification

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Mark across all aluminium bolts (1) with a colored mark.

Fig 15: Identifying Mark Across Aluminium Bolt Heads

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Tighten all aluminium bolts (1) only with special tool 00 9 120 .

Tightening torque 11 11 3AZ .

Tightening torque 11 11 4AZ .

Installation note:

All aluminium bolts must be equally positioned with respect to the colored mark after being fastened.

Fig 16: Tightening Aluminium Bolts

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Fit special tool 11 6 252 with magnetic foot on special tool 11 4 440.

Clamp special tool 11 6 251 on special tool 11 6 252 .

Position special tool 11 6 251 with button on the flat side of the crankshaft.

Press crankshaft (1) in direction of arrow up to stop.

Set dial gauge with knurled screw (2) on zero.

Fig 17: Pressing Crankshaft Up To Stop And Setting Dial Gauge On Zero

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Press crankshaft (1) in direction of arrow from right to left up to stop.

Determine CRANKSHAFT AXIAL CLEARANCE .

Fig 18: Pressing Crankshaft Up To Stop And Determining Crankshaft Axial Clearance

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Turn crankshaft (1) via the central bolt with special tool 00 2 010 to determine the COEFFICIENT OF FRICTION .

Fig 19: Turning Crankshaft And Determining Coefficient Of Friction

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Drive both injector nozzles (1) on left and right on crankcase into the bore hole (see arrow) with special tool 11 9 360 .

Installation note:

Replace injector nozzles (1).

Fig 20: Locating Injector Nozzles

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

Fig 21: Driving-In Injector Nozzle Using Special Tool 11 9 360

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Drive injector nozzle (1) all the way in.

Fig 22: Identifying Injector Nozzle

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Installation note:

Use PRIMER 1.3 AND LIQUID SEALING COMPOUND 1.4 .

Prepare liquid sealing compound (2) in special tool 11 4 370 .

Screw on nozzle (1) for injecting sealing compound.

Fig 23: Identifying Liquid Sealing Compound And Nozzle

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Slowly and evenly insert liquid sealing compound (1) via the injector nozzle with special tool 11 4 370 in direction of arrow.

Graphic N42.

Fig 24: Inserting Liquid Sealing Compound

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Replace CRANKSHAFT SEAL at front.

Replace CRANKSHAFT RADIAL SEAL (transmission side).

Assemble engine.