11 21 500 Replacing crankshaft (S63T 0)

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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 tasks:

Remove engine. See 11 00 598 REMOVING AND INSTALLING ENGINE ON FRONT AXLE (S63T 0) WITH GS7D36SG TRANSMISSION or 31 10 001 COMPLETELY REMOVING AND INSTALLING THE FRONT AXLE WITH ENGINE AND TRANSMISSION (S63T0, MANUAL GEARBOX) .
Mount engine on assembly stand. See 11 00 MOUNTING ENGINE ON ASSEMBLY STAND (S63T) .
Remove both cylinder heads. See 11 12 105 REMOVING AND INSTALLING LEFT CYLINDER HEAD (S63T 0) and 11 12 106 REMOVING AND INSTALLING RIGHT CYLINDER HEAD (S63T 0) .
Remove HUB FOR VIBRATION DAMPER
Remove OIL PUMP
Take off UPPER PART OF OIL SUMPS
REMOVE lower gear case cover
Removing PISTONS
Remove FLYWHEEL
Remove radial shaft seals. See 11 14 151 REPLACING CRANKSHAFT SEAL ON THE TRANSMISSION SIDE (S63T 0) and 11 14 141 REPLACING RADIAL SHAFT SEAL IN BOTTOM GEAR CASE COVER (S63T 0) .
Remove TIMING CHAINS

Installation note:

Layout of main bearing caps.

All numbers must be read from the cylinder bank (1 to 4) (see arrows in illustration).

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 main bearing taper screw mounting (1).

Release oil pump spacer bolt (2) (N63O 1).

Fig 3: Identifying Oil Pump Spacer Pins And Main Bearing Taper Screw Connection

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Release all threaded support sleeves (1).

Fig 4: Identifying Threaded Support Sleeves

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

Fig 5: Crankshaft Bolts (M8) Tightening/Loosening Sequence (S63T O)

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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 6: Crankshaft Bolts (M11) Tightening/Loosening Sequence (S63T O)

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Release screw for oil nozzle (1).

Tightening torque: 11 11 7 AZ .

Illustration: N63.

Fig 7: 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.

Illustration: N63.

Fig 8: Locating Oil Nozzle

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Replace CRANKSHAFT MAIN BEARING SHELLS .

Installation note:

Note arrangement of main bearing caps (1 to 5).

All numbers must be read from the cylinder bank (1 to 4) (see arrows in illustration).

Fig 9: 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.

Install crankshaft.

Fig 10: Identifying Main Bearing Caps

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Fit bearing caps (1 to 5).

Set down bearing caps positioned from 1 to 5.

Insert all collar bolts (M11) hand-tight.

Insert collar bolts (M11) in sequence (1 to 10).

Fig 11: Crankshaft Bolts (M11) Tightening/Loosening Sequence (S63T O)

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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 12: Identifying Mark On Collar Bolt Heads

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

Tightening torque 11 11 1 AZ .

Fig 13: 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 14: Crankshaft Bolts (M8) Tightening/Loosening Sequence (S63T O)

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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 15: Identifying Mark On Collar Bolt Heads

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

Tightening torque: 11 11 2AZ .

Fig 16: Securing Collar Bolt

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

Tightening torque: 11 11 3 AZ .

Fig 17: Identifying Threaded Support Sleeves

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Secure main bearing taper screw mounting (1).

Tightening torque: 11 11 4 AZ .

Fig 18: 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 19: 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 SIDE CLEARANCE .

Fig 20: Checking Crankshaft Axial Play

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Assemble engine.