Remove/install crankshaft

AR03.20-B-4351E

Remove/install crankshaft

12.02.16



Remove

1

Remove oil sump

Bus

AR01.45-B-7500F

Truck

AR01.45-B-7500E

2

Remove the oil pump

AR18.10-B-6020D

3

Remove the pistons

AR03.10-B-7021C

4

Remove the front cover with the sealant

AR01.40-B-8810A

5

Remove distribution casing

Engine 457.922/925/928/929/931

AR01.60-B-8200D

Engine 457.907/908/908/915/916/927/932

AR01.60-B-8200H

6

Loosen the screws (6) and remove the caps from the primary bearings (4) and (5)

 The caps of the primary bearings are numbered in sequential, ascending order, from the front of the engine.

7

Remove the crankshaft (1)

Screw one dowel pin at each end of the crankshaft. Tie using a sturdy rope and lift carefully using a suitable device (hoist).

Dowel pin

*403589026300

8

Remove the sleeves (2 and 2.1) from the block bearings and the sleeves (3 and 3.1) from the caps (5 and 4)

Mark the sleeves (2/2.1) and their respective bearings on the block, and the sleeves (3/3.1) and their respective caps (5/4). This procedure allows, in the event of reuse, installing the bearings on their original positions.

9

Properly clean all parts

10

Check the conditions and dimensions of the crankshaft and sleeves

If cracks are found on the crankshaft, replace it.

AR03.20-B-4355A



Install

11

Install the sleeves (2 and 2.1) on the block bearings and the sleeves (3 and 3.1) on the caps (5 and 4)

If the sleeves are reused, note the mark made when removing. The sleeves (2 and 2.1) are provided with holes for oil filling, which should match the existing holes on the block. The sleeve tabs should perfectly fit into the slots on the block and caps. The adjustment sleeves (2.1 and 3.1) should be mounted, respectively, on the 4th bearing and the 4th cap from the front of the engine.

To achieve the required radial clearance, the diameter of the sleeves and crankshaft necks should adhere to the prescribed tolerance ranges and belong to the same repair level.

AR03.20-B-4355-01A

*BE03.20-B-1001-02C

*BE03.20-B-1005-02C

*BE03.20-B-1007-02C

*BE01.40-B-1003-02D

 To achieve the required axial clearance, the width of the sleeves (2.1 and 3.1) and the crankshaft adjustment neck should adhere to the prescribed tolerance ranges and belong to the same repair level.

AR03.20-B-4355-02B

*BE03.20-B-1002-02C

*BE03.20-B-1004-02C

*BE03.20-B-1012-02C

12

Install the crankshaft (1) with the gears (9) and (10) correctly synchronized

Lubricate the friction surface of the sleeves and crankshaft necks with motor oil.

Screw one dowel pin at each end of the crankshaft. Tie with a sturdy rope and use a suitable lifting device (hoist).

The tooth marked on the crankshaft gear (10) should be positioned between the marked teeth of the valve camshaft gear (9).

Dowel pin.

*403589026300

13

Install the caps (4/5) of the primary bearings in the correct order and position

The caps of the primary bearings are numbered in sequential, ascending order, from the front of the engine. Dowel pins ensure the correct seating of the caps on the bearings.

14

Install the screws (6) of the caps of the primary bearings (4 and 5) and tighten them as recommended

 Before installing the screws (6), measure the length (L). Replace them if the length (L) is exceeded. Lightly lubricate the thread and the seating face of the screw heads.

*BE01.40-B-1003-02D



*BA01.40-B-1004-01H

15

Rotate the crankshaft (1) and check for smooth movement

If the crankshaft does not rotate freely, remove it and look for the root causes.

16

Measure the axial clearance of the crankshaft

Using the dial indicator (8) and the respective holder (7).

AR03.20-B-4355-02B

Axial clearance of the crankshaft.

*BE03.20-B-1004-02C



*001589532100



*363589022100

17

Install the distribution housing

Engine 457.922/925/928/929/931

AR01.60-B-8200D

Engine 457.907/908/909/915/916/927/932

AR01.60-B-8200H

18

Install the front cover with the sealant

AR01.40-B-8810A

19

Install the pistons

AR03.10-B-7021C

20

Install the oil pump

AR18.10-B-6020D

21

Install the oil sump

Bus

AR01.45-B-7500F

Truck

AR01.45-B-7500E

Número

Denominação

Engine 457.9 without CODE MS5

Engine 457.9; 460.984 with CODE MS5

BE03.20-B-1001-02C

Diameter of the main neck

Normal

mm

103.980...104.000

103.980...104.000

Normal I

mm

103.880...103.900

103.880...103.900

Repair I

mm

103.730...103.750

103.730...103.750

repair II

mm

103.480...103.500

103.480...103.500

repair III

mm

103.230...103.250

103.230...103.250

repair IV

mm

102.980...103.000

102.980...103.000

BE03.20-B-1002-02C

Width

of the main adjustment neck

Normal

mm

46.000...46.062

46.000...46.062

Repair I

mm

46.500...46.562

46.500...46.562

repair II

mm

47.000...47.062

47.000...47.062

of the other main necks

mm

-

46.000...46.250

BE03.20-B-1004-02C

Crackshaft axial clearance

mm

0.230...0.370

0.230...0.370

BE03.20-B-1005-02C

Radial play in the main necks

mm

0.060...0.126

0.060...0.126

BE03.20-B-1007-02C

Internal diameter of sleeves of the main necks (assembled)

Normal

mm

104.060...104.106

104.060...104.106

Normal I

mm

103.960...104.006

103.960...104.006

Repair I

mm

103.810...103.856

103.810...103.856

repair II

mm

103.560...103.606

103.560...103.606

repair III

mm

103.310...103.356

103.310...103.356

repair IV

mm

103.060...103.106

103.060...103.106

BE03.20-B-1012-02C

Necks matching radius

main

mm

4.2...4.5

4.2...4.5

connecting rods

mm

3.7...4.0

3.7...4.0

BE03.20-B-1014-02C

Main sleeves of axial adjustment width

Normal

mm

45.74...45.81

45.74...45.81

Repair I

mm

46.24...46.31

46.24...46.31

repair II

mm

46.74...46.81

46.74...46.81

Número

Denominação

Engine 457.9

BE01.40-B-1003-02D

Bolts attaching the main bearing caps

Thread diameter

M

18x2

Length (L) of new stretch bolt

mm

152,5...153,0

Length (L) max. permissible

mm

156,0

Número

Denominação

Engine 457.9

BA01.40-B-1004-01H

Bearing cap bolt in the crankshaft

1st stage

Nm

300...330

2nd stage

angular

90°...100°