11 21 500 Replacing crankshaft (N63)

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Special tools required:

IMPORTANT: Weight of crankshaft is approx. 20 kg.
Risk of injury from sharp edge of housing.

Necessary preliminary work:

Remove ENGINE
Mount engine on ASSEMBLY STAND .
Remove cylinder heads. See REMOVING LEFT CYLINDER HEAD and REMOVING RIGHT CYLINDER HEAD .
Remove HUB FOR VIBRATION DAMPER
Remove LOWER TIMING CASE COVER
Remove oil pan. See REMOVING LOWER OIL SUMP SECTION and REMOVING UPPER OIL SUMP SECTION .
Remove OIL PUMP
Remove PISTON
Remove FLYWHEEL
Remove radial shaft seals. See RADIAL SHAFT SEAL IN LOWER TIMING CASE COVER and CRANKSHAFT RADIAL SEAL 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).

Fig 1: Identifying Main Bearing Caps

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Main bearing caps (1 to 5) opposite the output end on the timing chain drive.

Fig 2: Identifying Main Bearing Caps

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Release oil pump spacer bolts (1) with special tool 13 5 020 .

Fig 3: Releasing Oil Pump Spacer Bolts

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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 Connection

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Release all threaded support sleeves (1).

Fig 5: Identifying Threaded Support Sleeves

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Release collar bolts (M8) in sequence 10 to 1.

Fig 6: Crankshaft Bolts (M8) 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: Crankshaft Bolts (M11) Tightening/Loosening Sequence (N63)

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Release screw for oil nozzle (1).

Tightening torque: 11 11 8AZ .

Fig 8: Identifying Screw For Oil Nozzle

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Installation note:

Check oil nozzle (1) for clear passage with compressed air.

Observe fastening on oil nozzle.

Fig 9: Locating Oil Nozzle

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Installation note:

Observe fastening in crankcase.

Fig 10: Identifying Installed Oil Nozzle

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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).

Fig 11: Identifying Main Bearing Caps

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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.

Fig 12: Identifying Main Bearing Caps

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Install crankshaft.

Fit bearing caps (1 to 5).

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: Crankshaft Bolts (M11) 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: Identifying Mark On Collar Bolt Heads

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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

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Insert all collar bolts (M8) hand-tight.

Secure collar bolts (M8) in sequence (1 to 10).

Fig 16: Crankshaft Bolts (M8) 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 17: Identifying Mark On Collar Bolt Heads

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Secure collar bolt (1) with special tool 00 9 120 .

Fig 18: Securing Collar Bolt

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Secure all threaded support sleeves (1) with special tool 11 4 350 .

Tightening torque: 11 11 3AZ .

Fig 19: Securing Threaded Support Sleeves

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Secure main bearing taper screw connection (1).

Tightening torque: 11 11 4AZ .

Secure oil pump spacer pins (2).

Tightening torque: 11 11 5AZ .

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

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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: Rotating 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: Checking Axial Play

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Assemble engine.