1 | Crankshaft |
2 | Top bearing shell (in the cylinder block) |
3 | Bottom bearing shell (in the bearing cap) |
4 | Compensating shims |
5 | Main bearing covers |
6 | Main bearing cap (thrust bearing) |
7 | Bearing cap screws |
8 | Crankshaft gear |
9 | Dowel pin |
B03.20-0002-06
B03.20-0001-09
1 | Crankshaft | 7 | Bearing cap screws | |
2 | Top bearing shell (in the cylinder block) | |||
3 | Bottom bearing shell (in the bearing cap) | 10 | Dial gauge | |
4 | Compensating shims | 11 | Gauge holder | |
5 | Main bearing covers | L | Bolt length | |
6 | Main bearing cap (thrust bearing) |
| Remove | ||
1 | Remove the engine |
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Engine 904.9, 924.9 in Type 384.06/07 | |||
2 | Remove the pistons |
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3 | Remove the oil pump |
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4 | Removing the timing case |
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5 | Remove the crankshaft gear (8) |
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6 | Unscrew the bolts (7), remove the main bearing caps (5) and the main (adjustment) bearing cap (6) | The end play shims (4) of the crankshaft (1) are installed in the main (adjustment) bearing (6). | |
7 | Identify the lower bushings (on the bearing cover) (3) with respect to their respective main bearing covers (5), and the main (adjusting) bearing cover (6) | This procedure will permit, in the case of bearing shell reutilization, the assembly in their respective original position. | |
8 | Remove crankshaft (1) from the engine block | Utilize a rope or soft material belt to avoid damaging the crankshaft (1) journals. | |
9 | Identify the top bearing shells (on the engine block) (2) in respect to their seats in the engine block | This procedure will permit, in the case of bearing shell reutilization, the assembly in their respective original position. | |
10 | Properly clean all parts | ||
| Check | ||
11 | Check the crankshaft (1) for damages or wear | ||
12 | With the utilization of an appropriate hardness tester, check the hardness of the main journals and of the connecting rod journals | .Hardness of main journals and connecting rod journals (Rockwell hardness) | |
13 | Check the crankshaft (1) for out of round | Mount the crankshaft (1) on the end journals. | |
.Crankshaft run-out (crankshaft mounted on the end journals) | |||
Dial gage | |||
Dial indicator holder | |||
14 | Check upper bushings (on engine block) (2), lower bushings (on bearing cover) (3) and their necks on crankshaft (1) |
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.Diameter of the main journals | |||
.Radial clearance on main journals | |||
.Inside diameter of main journal bearing shells (installed) | |||
.Basic bore diameter of main bearings (bearing shell housing) | |||
Dial gage | |||
15 | Measure the shank length (L) of the bearing cap bolts (7) | .bearing cap bolt | |
If the length (L) is longer than recommended, | |||
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Replace the bolts (7). | |||
| Install | ||
16 | With a chamois, clean the main bearing shell housings on the engine block and on the bearing caps | ||
17 | Install upper bushings (on engine block) (2) into engine block housings | Observe that the upper bearing shell alignment tabs (on the engine block) (2) seat perfectly in the engine block grooves. | |
The bearing shells (on the engine block) (2) installed in the engine block are fitted with an oil bore, which must coincide with the bores in the engine block. | |||
18 | Clean the oil galleries on the crankshaft (1) with a cylindrical brush and compressed air. Next, clean the journals with a chamois | ||
19 | Determine the thickness of the compensating thrust washers (4) |
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.Width | |||
.Axial clearance of shaft | |||
.Compensating washers thickness | |||
20 | Oil the upper bearing shells (on the engine block) (2) and carefully install the crankshaft (1) | Utilize a rope or soft material belt to avoid damaging the crankshaft (1) journals. | |
21 | Install the lower bushings (on the bearing cap) (3), the main bearing caps (5) and the main (adjusting) bearing cap (6) | Note that the lower bearing tabs (on the bearing cap) (3) fit perfectly into the main bearing caps (5) and the main (adjusting) bearing cap (6). | |
The bearing shell alignment tags of the engine block and of the bearing caps must be on the same side. Observe the marking generated by the removal. | |||
22 | Oil the shims (4) and install them in the bearing cap (adjustment) (6) | The compensating thrust washers (4) must be of the same thickness. | |
The oil grooves (arrows) of the compensating washers (4) must be directed to the contact face of the crankshaft (1). | |||
23 | Install the main bearing caps (5) and the main (adjustment) bearing cap (6) with the lower shells (on the bearing cover) (3) | The sequential number engraved on the bearing caps must be assembled starting from the engine front. | |
Lubricate the friction surface of the bearing shell. | |||
24 | Install the bearing cap screws (7) | Lightly oil the thread and the head seat face of the bearing cap screws (7). | |
Follow the specified tightening stages. | |||
.Main bearing cap bolts to engine block | |||
25 | Spin the crankshaft (1) manually checking its operating smoothness | ||
26 | Measure the axial clearance of the crankshaft (1) | .Axial clearance of shaft | |
Dial gage | |||
Dial indicator holder | |||
27 | Install the crankshaft gear (8) |
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28 | Install the pistons |
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29 | Install the oil pump |
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30 | Install the distribution housing |
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31 | Replace the engine oil filter element | ||
| . | ||
32 | Install engine |
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Engine 904.9, 924.9 in Type 384.06/07 |
Engine block test values |
Number | Designation | Engine 904.9, 906.9 | Engine 924.9, 926.9 | ||
BE01.40-B-1010-02C | bearing cap bolt | Thread diameter | M | 14 | 14 |
Rod length in state new | mm | 113,5...114,0 | 113,5...114,0 | ||
Body length | mm | 116 | 116 | ||
Thread diameter | M | 14 | 14 | ||
Rod length in state new | mm | 133,5 ... 134,0 | 133,5...134,0 | ||
Body length | mm | 136 | 136 |
Crankshaft test values |
Number | Designation | Engine 904.9 | Engine 906.9; 926.9; 924.9 | ||
BE03.20-B-1001-02C | Diameter of the main journals | standard | mm | 85,990...86,010 | 85,990...86,010 |
standard I | mm | 85,890...85,910 | 85,890...85,910 | ||
repair stage I | mm | 85,740...85,760 | 85,740...85,760 | ||
repair stage II | mm | 85,490...85,510 | 85,490...85,510 | ||
repair stage III | mm | 85,240...85,260 | 85,240...85,260 | ||
repair stage IV | mm | 84,990...85,010 | 84,990...85,010 |
Crankshaft test values |
Number | Designation | Engine 904.9 | Engine 906.9; 926.9; 924.9 | |||
BE03.20-B-1002-02C | Width | of main thrust bearing | standard | mm | 31,000...31,100 | 31,000...31,100 |
repair stage I | mm | 31,300...31,400 | 31,300...31,400 | |||
repair stage II | mm | 31,500...31,600 | 31,500...31,600 | |||
of the other main journals | mm | 31,0...31,2 | 31,0...31,2 |
Crankshaft test values |
Number | Designation | Engine 904.9 | Engine 906.9; 926.9; 924.9 | ||
BE03.20-B-1007-02C | Inside diameter of main journal bearing shells (installed) | standard | mm | 86,066...86,108 | 86,066...86,108 |
standard I | mm | 85,966...86,008 | 85,966...86,008 | ||
repair stage I | mm | 85,816...85,858 | 85,816...85,858 | ||
repair stage II | mm | 85,566...85,608 | 85,566...85,608 | ||
repair stage III | mm | 85,316...85,358 | 85,316...85,358 | ||
repair stage IV | mm | 85,066...85,108 | 85,066...85,108 |
001 589 53 21 00
Dial gage
363 589 02 21 00
Dial indicator holder