11 21 500 Replacing crankshaft (N16)

Special tools required:

WARNING: Rotating components (danger of injury!).
It is essential to follow the procedure described below and the instructions on handling the special tools.

IMPORTANT: The jointing torque and angle of rotation must be observed without fail (risk of damage) .

Necessary preliminary tasks:

Remove ENGINE .
Mount engine on ASSEMBLY STAND .
Remove VIBRATION DAMPER .
Removing OIL SUMP .
Remove OIL PUMP .
Remove TIMING CHAIN .
Remove CYLINDER HEAD .
Remove FLYWHEEL .

Release screws (1).

Tightening torque: 11 13 3AZ .

Remove oil deflector (2).

Remove all PISTONS .

Fig 1: Identifying Oil Deflector And Screws

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Drive out cover plates (1) with a cross-cut chisel (2).

Fig 2: Driving Out Cover Plates With Cross-Chisel

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Release screws (28 to 11).

Release screws (10 to 1).

Fig 3: Lower Crankcase Bolts Tightening Sequence

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Release crankcase lower section in direction of arrow with a regular screwdriver (2) and an open-end spanner (1) at press-off lug.

Fig 4: Releasing Crankcase Lower Half

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Remove both radial shaft seals (1).

Fig 5: Identifying Radial Shaft Seals

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Remove crankshaft (1).

IMPORTANT: Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 19 kg.

Remove MAIN BEARING SHELLS , replace if necessary.

Fig 6: Identifying Crankshaft

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IMPORTANT: Do not clean sealing surfaces with a metal-cutting tool.

Clean sealing surfaces with special tools 11 4 471 and 11 4 472 .

Fig 7: Cleaning Sealing Surfaces With Special Tools (11 4 471) And (11 4 472)

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Apply sealing bead (1) to crankcase lower section (see illustration) with Loctite 5970 sealing compound.

Installation note:

Follow manufacturer's instructions (Loctite).

Fig 8: Crankcase Lower Half Sealing Bead Application Area

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Apply sealing bead (1) to crankcase upper section (see illustration) with Loctite 5970 sealing compound.

Apply a light coating of engine oil to bearings.

Fig 9: Crankcase Upper Half Sealing Bead Application Area

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Insert crankshaft (1).

IMPORTANT: Rotating component (danger of injury!)
Insert crankshaft with aid of a second person.
Weight of crankshaft approx. 19 kg.

Fig 10: Identifying Crankshaft

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Lubricate all bearings from 1 to 5 with engine oil.

Install crankcase lower section.

Position crankcase lower section using two dowel pins on the crankcase upper section.

Fig 11: Identifying Bearings

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Tighten bolts (1 to 10).

Tightening torque: 11 11 1AZ .

Tighten bolts (11 to 28).

Tightening torque: 11 11 2AZ .

Fig 12: Lower Crankcase Bolts Tightening Sequence

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Only use special tool to secure bolts 00 9 120 .

IMPORTANT: Jointing torque and angle of rotation must be observed without fail.

Fig 13: Tightening Bolts Using Special Tool (00 9 120)

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To prevent oil leakage, apply a thin coating of LOCTITE 648 to cover sleeve (1) in area (2).

Fig 14: Identifying Loctite Application Area On Cover Sleeve

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Knock in cover sleeves with special tool 23 1 240 as far as they will go.

Fig 15: Installing Cover Sleeves With Special Tool

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Determine SIDE CLEARANCE of crankshaft.

Affix special tool 11 6 252 with magnet.

Set special tool 11 6 251 to zero.

Press crankshaft in direction of arrow to the limit position.

Fig 16: Checking Side Clearance Of Crankshaft Using Special Tools (11 6 252) And (116 251)

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Replace radial shaft seal at FRONT .

Replace radial shaft seal at REAR .

Assemble engine.