Remove/install crankshaft

AR03.20-W-4351J

Remove/install crankshaft

23.11.10



Removing

1

Remove engine

Model 375.1, 958.0, 970, 972, 974, 975, 976

AR01.10-W-2400JC

Model 957

AR01.10-W-2400C

Model 375.3, 950, 952, 953, 954, 958.2

AR01.10-W-2400J

2

Remove timing case

Engine 900.9, 924.9

AR01.60-W-8200JA

Engine 902.9, 925.9, 926.9

AR01.60-W-8200J

3

Remove oil pump

Model 375, 950, 952, 953, 954, 958, 970, 972, 974, 975, 976

AR18.10-W-6020J

Model 957

AR18.10-W-6020JB

4

Remove pistons

AR03.10-W-7021J

5

Remove main bearing cap (5) and main fitted bearing cap (6)

Check the identification on main bearing cap (5) and main bearing fitted bearing cap (6), and mark them again if necessary.

6

Remove thrust plates (4) from main fitted bearing cap (6)

7

Remove main bearing shells (3) from main bearing caps (5) and main fitted bearing cap (6)

 Mark the main bearing shells (3) corresponding to the related main bearing cap (5) and main fitted bearing cap (6).

8

Screw centering drifts into the front and rear of crankshaft (1) and fasten a suitable shackle to them

 Alignment punch

*904589026300

9

Lift crankshaft (1) out of cylinder crankcase (10) with the shackle, and place to one side

10

Take off crankshaft sprocket (8)

11

Take main bearing shells (2) out of cylinder crankcase (10)

 Mark the main bearing shells (2) relative to cylinder crankcase (10).

12

Clean crankshaft (1) and oil duct in the crankshaft (1) and check for continuity



Check

13

Carry out a visual inspection of crankshaft (1) to check for damage, cracking and galling

 If damage, cracks or galling are found, replace the crankshaft (1).

14

Clean main bearing shells (2, 3) and main bearing journals on the crankshaft (1) with a chamois leather and carry out a visual inspection to check for wear



Information on assessing wear of main bearings and main bearing journals

AH03.20-N-1000-02A

15

Measure concentricity of crankshaft (1) at middle main bearing journal

AR03.20-W-4351-08J

*BE03.20-N-1011-02B

Dial gage

*001589532100

Dial gauge holder

*363589022100

16

Inspect hardness of main and connecting rod bearing journals

AR03.20-W-4351-09J

*BE03.20-N-1013-02B

Hardness tester

*000589202100



Notes on hardness test

AH00.00-N-0012-01A

17

Determine crankshaft bearing radial play

AR03.20-W-4291-02J

Main bearing journal diameter

*BE03.20-N-1001-02B

Fitted bearing journal width

*BE03.20-N-1002-02B

Main bearing journal width

*BE03.20-N-1003-02B

Radial play

*BE03.20-N-1007-02B

Main bearing inner diameter

*BE03.20-N-1015-02B



*BA01.40-N-1001-01C

 Dial indicator

*001589532100

18

Determine connecting rod bearing radial play

AR03.20-W-4291-04J

Connecting rod bearing inside dia. with connecting rod bearing shells inserted

*BE03.10-N-1001-01B

Connecting rod bearing play

*BE03.10-N-1003-01B

Connecting rod bolt

*BE03.10-N-1013-01B

Connecting rod bearing journal dia.

*BE03.20-N-1004-02B

Connecting rod journal width

*BE03.20-N-1005-02B



*BA03.10-N-1001-01B

 Dial indicator

*001589532100

 Socket wrench bit

*422589020900

19

Mount crankshaft (1) axially

 The main fitted bearing cap (6) must be installed.

AR03.20-W-4355-02J

Fitted bearing journal width

*BE03.20-N-1002-02B

Axial play

*BE03.20-N-1006-02B

Wall thickness of fitted bearing thrust washers

*BE03.20-N-1016-02B

 Dial indicator

*001589532100

 Dial indicator holder

*363589022100

20

Measure bolts (7)

If permissible shank length (L) is exceeded, replace bolt (7) concerned.

Main bearing cover bolt 114 mm

*BE01.40-N-1010-02B

Main bearing cover bolt 134 mm

*BE01.40-N-1020-02B

21

Check dowel pin (9) in crankshaft (1) for damage, and check for tight seating

 Replace dowel pin (9) if necessary.



Install

22

Remove metal dust from the internal components

 Only if bearing damage has occurred. Remove potential metal dust from oil ducts and clean internal components.

23

Coat the bearing surfaces of main bearing shells (2) with engine oil

24

Insert main bearing shells (2) in cylinder crankcase (10)

 Note identification marks and installation positions of main bearing shells (2) in cylinder crankcase (10).

 The oil holes in main bearing shells (2) must be aligned with the oil holes in cylinder crankcase (10), otherwise the bearings may be damaged.

25

Using the shackle, set crankshaft (1) on main bearing shells (2) in cylinder crankcase (10)

26

Remove shackle and centering drifts from crankshaft (1)

27

Coat bearing surfaces of main bearing shells (3) and thrust plates (4) with engine oil

28

Insert main bearing shells (3) in main bearing caps (5) and main fitted bearing cap (6)

 Note identification marks and installation positions of main bearing shells (3) corresponding to the related main bearing cap (5) and main fitted bearing cap (6).

29

Install main fitted bearing cap (6) with main bearing shell (3) inserted, and thrust plates (4)

 Note installation position of thrust plates (4). The oil grooves (arrows) must point upwards.

30

Install main bearing caps (5) with the main bearing shells (3) inserted

 Observe installation position of main bearing cap (5). The main bearing caps (5) are marked and must be installed in increasing order starting at the front. The main bearing caps (5) are shaped asymmetrically and can only be mounted in one position.

31

Coat bolt (7) with engine oil, insert them in main bearing caps (5) and main fitted bearing cap (6), and tighten them



*BA01.40-N-1001-01C

32

Turn crankshaft (1) by hand, and check for unobstructed movement

33

Determine crankshaft bearing crankshaft end play (1)

 If the crankshaft bearing axial play is outside the permitted tolerance, inspect thrust plates (4).

AR03.20-W-4291-03J

*BE03.20-N-1006-02B

 Dial indicator

*001589532100

 Dial indicator holder

*363589022100

34

Perform additional checking work for engine repair on crankshaft (1)

AR03.20-W-0002J

35

Attach crankshaft gear (8) and align with camshaft sprocket (11)

 The markings (arrows) on crankshaft gear (8) and camshaft sprocket (11) must be aligned with each other, otherwise turn the crankshaft (1) or camshaft sprocket (11) as necessary.

36

Install pistons

AR03.10-W-7021J

37

Install oil pump

Model 375, 950, 952, 953, 954, 958, 970, 972, 974, 975, 976

AR18.10-W-6020J

Model 957

AR18.10-W-6020JB

38

Install timing case

Engine 900.9, 924.9

AR01.60-W-8200JA

Engine 902.9, 925.9, 926.9

AR01.60-W-8200J

39

Install engine

Model 375.1, 958.0, 970, 972, 974, 975, 976

AR01.10-W-2400JC

Model 957

AR01.10-W-2400C

Model 375.3, 950, 952, 953, 954, 958.2

AR01.10-W-2400J

40

Fill engine oil circuit

AR18.00-W-1600J

Number

Designation

Engine
900.9,
Engine
902.9
without code MS8

BE01.40-N-1010-02B

Main bearing cover bolt

Thread diameter

M

14

Length of shank when new

mm

114.0

Shank length

mm

116.0

BE01.40-N-1020-02B

Main bearing cover bolt

Thread diameter

M

14

Length of shank when new

mm

134.0

Shank length

mm

136.0

Number

Designation

Engine
924.9, 925.9, 926.9 without code MS4 or MS5

Engine
924.9, 925.9, 926.9 with code MS4 or MS5

BE01.40-N-1010-02B

Main bearing cover bolt

Thread diameter

M

14

14

Length of shank when new

mm

114.0

114.0

Shank length

mm

116.0

116.0

BE01.40-N-1020-02B

Main bearing cover bolt

Thread diameter

M

14

14

Length of shank when new

mm

134.0

134.0

Shank length

mm

136.0

136.0

Number

Designation

Engine
900.9, 902.9,
engine 904.9 as of end no. 119309,
engine
906.9 as of end no. 119309

Engine
924.9, 925.9, 926.9 without code MS4 or MS5

BE03.10-N-1001-01B

Connecting rod bearing inside dia. with connecting rod bearing shells inserted

Default

mm

70.054 to 70.093

70.054 to 70.093

Deviation 0.1

mm

69.954 to 69.993

69.954 to 69.993

Deviation 0.25

mm

69.804 to 69.843

69.804 to 69.843

Deviation 0.5

mm

69.554 to 69.593

69.554 to 69.593

Deviation 0.75

mm

69.304 to 69.343

69.304 to 69.343

Deviation 1.0

mm

69.054 to 69.093

69.054 to 69.093

BE03.10-N-1003-01B

Connecting rod bearing play

radial

mm

0.039 to 0.098

0.039 to 0.098

axial

mm

0.170 to 0.470

0.170 to 0.470

BE03.10-N-1013-01B

Connecting rod bolt

Thread

M

121.25

121.25

Shank length (L) when new

mm

56.0

56.0

Shank length (L)

mm

57.0

57.0

Number

Designation

Engine
924.9, 925.9, 926.9 with code MS4 or MS5

BE03.10-N-1001-01B

Connecting rod bearing inside dia. with connecting rod bearing shells inserted

Default

mm

70.054 to 70.093

Deviation 0.1

mm

69.954 to 69.993

Deviation 0.25

mm

69.804 to 69.843

Deviation 0.5

mm

69.554 to 69.593

Deviation 0.75

mm

69.304 to 69.343

Deviation 1.0

mm

69.054 to 69.093

BE03.10-N-1003-01B

Connecting rod bearing play

radial

mm

0.039 to 0.098

axial

mm

0.170 to 0.470

BE03.10-N-1013-01B

Connecting rod bolt

Thread

M

121.25

Shank length (L) when new

mm

56.0

Shank length (L)

mm

57.0

Number

Designation

Engine
900.9

Engine
902.9
without code MS8

BE03.20-N-1001-02B

Main bearing journal diameter

Default

mm

85.990 to 86.010

85.990 to 86.010

Deviation -0.1

mm

85.890 to 85.910

85.890 to 85.910

Deviation -0.25

mm

85.740 to 85.760

85.740 to 85.760

Deviation -0.5

mm

85.490 to 85.510

85.490 to 85.510

Deviation -0.75

mm

85.240 to 85.260

85.240 to 85.260

Deviation -1.0

mm

84.990 to 85.010

84.990 to 85.010

BE03.20-N-1002-02B

Fitted bearing journal width

Standard dia.

mm

85.990 to 86.010

85.990 to 86.010

Standard width

mm

31.000 to 31.062

31.000 to 31.062

Dia. deviation -0.1

mm

85.890 to 85.910

85.890 to 85.910

Standard width

mm

31.000 to 31.062

31.000 to 31.062

Dia. deviation -0.1

mm

85.890 to 85.910

85.890 to 85.910

Width deviation 0.3

mm

31.300 to 31.362

31.300 to 31.362

Dia. deviation -0.25

mm

85.740 to 85.760

85.740 to 85.760

Width deviation 0.3

mm

31.300 to 31.362

31.300 to 31.362

Dia. deviation -0.5

mm

85.490 to 85.510

85.490 to 85.510

Width deviation 0.5

mm

31.500 to 31.562

31.500 to 31.562

Dia. deviation -0.75

mm

85.240 to 85.260

85.240 to 85.260

Width deviation 0.5

mm

31.500 to 31.562

31.500 to 31.562

Dia. deviation -1.0

mm

84.990 to 85.010

84.990 to 85.010

Width deviation 0.5

mm

31.500 to 31.562

31.500 to 31.562

BE03.20-N-1003-02B

Main bearing journal width

mm

31.0 to 31.2

31.0 to 31.2

BE03.20-N-1004-02B

Connecting rod bearing journal dia.

Default

mm

69.995 to 70.015

69.995 to 70.015

Deviation -0.1

mm

69.895 to 69.915

69.895 to 69.915

Deviation -0.25

mm

69.745 to 69.765

69.745 to 69.765

Deviation -0.5

mm

69.495 to 69.515

69.495 to 69.515

Deviation -0.75

mm

69.245 to 69.265

69.245 to 69.265

Deviation -1.0

mm

68.995 to 69.015

68.995 to 69.015

BE03.20-N-1005-02B

Connecting rod journal width

mm

34.0 to 34.2

34.0 to 34.2

BE03.20-N-1006-02B

Axial play

mm

0.16 to 0.38

0.16 to 0.38

BE03.20-N-1007-02B

Radial play

mm

0.056 to 0.118

0.056 to 0.118

BE03.20-N-1011-02B

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

mm

0.11

0.15

BE03.20-N-1013-02B

Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)

HRC

52

52

BE03.20-N-1015-02B

Main bearing inner diameter

Default

mm

86.066 to 86.108

86.066 to 86.108

Deviation 0.1

mm

85.966 to 86.008

85.966 to 86.008

Deviation 0.25

mm

85.816 to 85.858

85.816 to 85.858

Deviation 0.5

mm

85.566 to 85.608

85.566 to 85.608

Deviation 0.75

mm

85.316 to 85.358

85.316 to 85.358

Deviation 1.0

mm

85.066 to 85.108

85.066 to 85.108

BE03.20-N-1016-02B

Wall thickness of fitted bearing thrust washers

Default

mm

3.240 to 3.310

3.240 to 3.310

Deviation 0.3

mm

3.390 to 3.460

3.390 to 3.460

Deviation 0.5

mm

3.490 to 3.560

3.490 to 3.560

Number

Designation

Engine
924.9, 925.9, 926.9

BE03.20-N-1001-02B

Main bearing journal diameter

Default

mm

85.990 to 86.010

Deviation -0.1

mm

85.890 to 85.910

Deviation -0.25

mm

85.740 to 85.760

Deviation -0.5

mm

85.490 to 85.510

Deviation -0.75

mm

85.240 to 85.260

Deviation -1.0

mm

84.990 to 85.010

BE03.20-N-1002-02B

Fitted bearing journal width

Standard dia.

mm

85.990 to 86.010

Standard width

mm

31.000 to 31.062

Dia. deviation -0.1

mm

85.890 to 85.910

Standard width

mm

31.000 to 31.062

Dia. deviation -0.1

mm

85.890 to 85.910

Width deviation 0.3

mm

31.300 to 31.362

Dia. deviation -0.25

mm

85.740 to 85.760

Width deviation 0.3

mm

31.300 to 31.362

Dia. deviation -0.5

mm

85.490 to 85.510

Width deviation 0.5

mm

31.500 to 31.562

Dia. deviation -0.75

mm

85.240 to 85.260

Width deviation 0.5

mm

31.500 to 31.562

Dia. deviation -1.0

mm

84.990 to 85.010

Width deviation 0.5

mm

31.500 to 31.562

BE03.20-N-1003-02B

Main bearing journal width

mm

31.0 to 31.2

BE03.20-N-1004-02B

Connecting rod bearing journal dia.

Default

mm

69.995 to 70.015

Deviation -0.1

mm

69.895 to 69.915

Deviation -0.25

mm

69.745 to 69.765

Deviation -0.5

mm

69.495 to 69.515

Deviation -0.75

mm

69.245 to 69.265

Deviation -1.0

mm

68.995 to 69.015

BE03.20-N-1005-02B

Connecting rod journal width

mm

34.0 to 34.2

BE03.20-N-1006-02B

Axial play

mm

0.16 to 0.38

BE03.20-N-1007-02B

Radial play

mm

0.056 to 0.118

BE03.20-N-1011-02B

Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)

mm

0.15

BE03.20-N-1013-02B

Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)

HRC

52

BE03.20-N-1015-02B

Main bearing inner diameter

Default

mm

86.066 to 86.108

Deviation 0.1

mm

85.966 to 86.008

Deviation 0.25

mm

85.816 to 85.858

Deviation 0.5

mm

85.566 to 85.608

Deviation 0.75

mm

85.316 to 85.358

Deviation 1.0

mm

85.066 to 85.108

BE03.20-N-1016-02B

Wall thickness of fitted bearing thrust washers

Default

mm

3.240 to 3.310

Deviation 0.3

mm

3.390 to 3.460

Deviation 0.5

mm

3.490 to 3.560

Number

Designation

Engines 900.9, 902.9, 904.9, 906.9

Engine 924.9, 925.9, 926.9

BA01.40-N-1001-01C

Bolt from main bearing cap to crankcase

Stage 1

Nm

30

30

Stage 2

Nm

80

80

Stage 3

Nm

155

155

Stage 4

°

90

90

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

Engine
924.9, 925.9, 926.9

BA03.10-N-1001-01B

Bolt of connecting rod bearing cap to connecting rod

Stage 1

Nm

10

10

Stage 2

Nm

45

45

Stage 3

°

90

90