Remove/install crankshaft

AR03.20-B-4351TA

Remove/install crankshaft

12.02.16



Remove

1

Remove the engine

Type 958.0

AR01.10-B-2400TD

Type 958.2

AR01.10-B-2400TF

2

Remove the piston

AR03.10-B-7021TA

3

Remove the oil pump

AR18.10-B-6020TA

4

Remove the timing case

Engine 904.9,

Engine 906.9 without rear drive

AR01.60-B-8200TA

Engine 906.9 with rear drive

AR01.60-B-8200TF

5

Detach the crankshaft gear (8) from the crankshaft flange

6

Disassemble the main shaft cap

 Main shaft bearing (5, 6) of the sequence after numerical identification.

In the engine 904 are installed in the 5th main bearing cap (6) the thrust washers (thrust bearing) (4).

In the engine 906 are installed in the 7th main bearing cap (6) the thrust washers (thrust bearing) (4).

7

Lift out the crankshaft bearing shells (3) from the main bearing caps (5, 6)

 Mark the crankshaft bearing shells (3) corresponding to each main bearing cap (5, 6).

8

Remove the crankshaft (1) from the cylinder block

Utilize a rope or some soft material belt in order not to damage the crankshaft journals (1).

9

Remove the bearing shells from the crankshaft journals (2) from the cylinder block

 Mark the crankshaft bearing shells (2) corresponding for the cylinder block.

10

Check the crankshaft bearing shells (2, 3) and the positioning pin of the crankshaft gear (1) wipe with a chamois and check for wear

 In the case of wear:



Measure and assemble the crankshaft (1).

AR03.20-B-4355TB



Indication on wear evaluation of the main bearing and of the main bearing journal

AH03.20-B-1000-02A

11

Clean the main oil gallery

 Only when there are shavings in the oil circuit.

AR01.40-B-8501TA

12

Crankshaft oil gallery (1) clean with compressed air and check for the passage

13

Measure the bolts of the main bearing cap (7)

 If the thread length (L) is exceeded:



*BE01.40-B-1010-02C

Replace the corresponding main bearing cap bolt (7).



Installing

14

Position the crankshaft bearing shells (2) in the cylinder block

 Observe the marking for the housing in the cylinder block

15

Install the crankshaft (1) with a hook

 Fasten the hook with bolts existing on the pulley and on the flywheel and fasten on the crankshaft (1).

16

Install the crankshaft bearing shells (3) in the main bearing caps (5, 6)

 Observe the marking for the main bearing cap (5, 6).

17

Install the main bearing cap (5)

The sequential number engraved on the bearing caps must be assembled starting from the engine front.

The assembly of the main bearing caps (5) must correspond to the numbers of the cylinder block starting at the front and assembled gradually in the sequence and cannot be swapped.



*BA01.40-B-1001-01B

18

Determining the thickness of the thrust washers (4) and install in the main bearing cap (6)

AR03.20-B-4351-01TB

Width of the main bearing journal

*BE03.20-B-1001-02C

Axial clearance

*BE03.20-B-1004-02C

Thickness of the thrust bearing's thrust washers

*BE03.20-B-1008-02C



*BA01.40-B-1001-01B



*001589532100



*363589022100

19

Assemble the crankshaft gear (8) on the crankshaft flange

 To position the crankshaft, the gear (8) marking "l" on the crankshaft gear (8) must fit between the markings "l - l" of the camshaft gear(10) (arrow).

20

Install the piston

AR03.10-B-7021TA

21

Install the oil pump

AR18.10-B-6020TA

22

Install the timing case

Engine 904.9,

Engine 906.9 without rear drive

AR01.60-B-8200TA

Engine 906.9 with rear drive

AR01.60-B-8200TF

23

Replace the oil interchanger

 Only when there are shavings in the oil circuit.

Engine 904.9

AR18.30-B-6840TA

Engine 906.9

AR18.30-B-6840TD

24

Install the engine

Type 958.0

AR01.10-B-2400TD

Type 958.2

AR01.10-B-2400TF

25

Fill the engine oil circuit with engine oil

AR18.00-B-1600TA

Número

Denominação

Engine 904.9 and 906.9

Engine 924.9 and 926.9

BE01.40-B-1010-02C

bearing cap bolt

Thread diameter

M

14

14

Length of the rod in new piece condition

mm

113,5...114,0

113,5...114,0

Body's length

mm

116

116

Thread diameter

M

14

14

Length of the rod in new piece condition

mm

133,5 ... 134,0

133,5...134,0

Body's length

mm

136

136

Número

Denominação

Engine 924.9, 926.9 with code MS5

BE01.40-B-1010-02C

bearing cap bolt

Thread diameter

M

14

Length of the rod in new piece condition

mm

113,5...114,0

Body's length

mm

116

Thread diameter

M

14

Length of the rod in new piece condition

mm

133,5...134,0

Body's length

mm

136

Número

Denominação

Engine 904.9

Engine 902.9; 906.9, 924.9, 926.9

BE03.20-B-1001-02C

Diameter of the main neck

Normal

mm

85.990...86.010

85.990...86.010

Normal I

mm

85.890...85.910

85.890...85.910

Repair I

mm

85.740...85.760

85.740...85.760

repair II

mm

85.490...85.510

85.490...85.510

repair III

mm

85.240...85.260

85.240...85.260

repair IV

mm

84.990...85.010

84.990...85.010

BE03.20-B-1004-02C

Crackshaft axial clearance

mm

0.16...0.38

0.16...0.38

BE03.20-B-1008-02C

Compensating washers thickness

Normal

mm

3.240...3.310

3.240...3.310

Repair I

mm

3.390...3.460

3.390...3.460

repair II

mm

3.490...3.560

3.490...3.560

Número

Denominação

Engine 900.9, 902.9, 904.9; 906.9

Engine 924.9; 926.9

BA01.40-B-1001-01B

Main bearing cap bolts to engine block

1st stage

Nm

30

30

2nd stage

Nm

80

80

3rd stage

Nm

155

155

4th stage

Degrees

90°

90°