A03.20-0003-06
1 Crankshaft
2 Bearing shell (cylinder crankcase)
3 Fitted bearing shell (cylinder crankcase)
4 Bearing shell (bearing cap)
5 Fitted bearing shell (bearing cap)
6 Bearing cap
7 Fitted bearing cap
8 Bolt
L Shank length
A03.20-0005-01
Radial bearing
2 Bearing shell (crankcase)
4 Bearing shell (bearing cap)
6 Bearing cap
Fitted bearing
3 Fitted bearing shell (crankcase)
5 Fitted bearing shell (bearing cap)
7 Fitted bearing cap
A03.20-0004-01
A03.20-0006-01
11 Camshaft sprocket
12 Crankshaft sprocket
| Removing | ||
1 | Remove engine | ||
2 | Remove alternator | Alternator I. | |
3 | Remove alternator support | | |
4 | Remove belt pulley, vibration damper | ||
5 | Remove pistons | ||
6 | Remove starter | ||
7 | Remove flywheel | ||
8 | Remove oil pressure relief valve | ||
9 | Remove oil pump | ||
10 | Remove end cover together with radial shaft sealing ring | ||
11 | Remove timing case | ||
12 | Remove bearing cap (6), fitted bearing cap (7) with bearing shells (4) and fitted bearing shell (5) | Identify bearing shells (4) and bearing caps (6) belonging together. | |
13 | Remove crankshaft (1) | Screw in one drift per crankshaft end. Lift crankshaft (1) out of crankcase carefully (for example with a hemp rope and a suitable lifting device). | |
Possibly remove bearing shells (2, 4) stuck to the crankshaft (1) and mark according to the associated bearing seat. | |||
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14 | Remove bearing shells (2) and fitted bearing shell (3) | Identify bearing shells and the respective bearing seat in the crankcase. | |
15 | Clean all parts. | Clean crankshaft, crankshaft bearings and bearing seats with a chamois leather. Blow out oil ducts of the crankcase (from the oil pump side) and oil ducts of the crankshaft with compressed air. | |
| Checking | ||
16 | Measure crankshaft (1), mount in bearings | ||
17 | Check shank length (L) of bolts (8). | If permissible shank length (L) of bolts (8) is exceeded, replace them. | |
| Install | ||
18 | Insert bearing shells (2) and fitted bearing shell (3), and oil bearing surfaces | Pay attention to applied markings in the case of used bearing shells (2). Insert fitted bearing shell (3) in the fourth main bearing. The locking lugs for bearing shells (2) and fitted bearing shell (3) must fit in the grooves of basic bores of the crankcase (arrows). | |
Oil holes in bearing shells (2), the fitted bearing shell (3) and crankcase must match. | |||
19 | Insert bearing shells (4) into bearing caps (6), the fitted bearing shell (5) into the fitted bearing cap (7), and oil the bearing surfaces | In the case of worn bearing shells (4) and fitted bearing shell (5) observe markings. | |
The locking lugs for bearing shells (4) and the fitted bearing shell (5) must fit in grooves of the bearing caps (arrows). | |||
20 | Lubricate crankshaft (1) journals and install crankshaft (1) | Screw in one drift per crankshaft end. Insert crankshaft (1) into crankcase carefully (for example with a hemp rope and a suitable lifting device). | |
The marked teeth on the cam (11) and crankshaft gear (12) must coincide. | |||
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21 | Insert bearing caps (6) and fitted bearing caps (7), apply pressure by hand and bolt tightly | Observe any markings. The bearing caps are numbered in ascending order beginning on the side of the vibration damper. Pay attention to position of guide studs. | |
Lightly oil the bolts (8) on thread and on contact surface of the screw head. | |||
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22 | Check crankshaft for light running | Rotate crankshaft by hand. In the case of sluggishness loosen bolts for individual bearing caps one after the other in order to localize the sluggish crankshaft bearing. | |
23 | Determine crankshaft axial play | ||
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24 | Install timing case | ||
25 | Install end cover together with radial shaft sealing ring | ||
26 | Install oil pump | ||
27 | Install oil pressure relief valve | ||
28 | Install flywheel | ||
29 | Install starter | ||
30 | Install pistons | ||
31 | Install belt pulley, vibration damper | ||
32 | Install alternator support | | |
33 | Install alternator | Alternator I. | |
34 | Install engine |
Test specifications for crankcase
Number | Designation | Engine 457.9 | ||
BE01.40-N-1004-02I | Bolts for crankshaft bearing caps | Thread dia. | M | 182 |
Shank length (L) when new | mm | 152.5 to 153.0 | ||
permissible shank length (L) | mm | 156 | ||
Check values for a crankshaft
Crankcase, timing case cover, end cover
Number | Designation | Engine | ||||
BA01.40-N-1004-01L | Bolt, crankshaft bearing cap to crankcase | Stage 1 | Nm | 300 | ||
Stage 2 | ° | 90 | ||||
Alternator
Number | Designation | Engine | ||
BA15.40-N-1006-01K | Bolt, alternator carrier at crankcase | M10 | Nm | 60 |
M141.5 | Nm | 160 | ||
001 589 53 21 00
Dial indicator holder
Dial indicator
Drift
403 589 02 63 00
363 589 02 21 00