Measure crankshaft and remount in bearings

AR03.20-B-4355TB

Measure crankshaft and remount in bearings

12.02.16



Inspect

1

Remove the crankshaft (1)

AR03.20-B-4351TA

2

Clean the engine parts

 After damage to the neck, filings need to be removed:



Clean the primary oil gallery.

AR01.40-B-8501TA

3

Clean the crankshaft (1)

4

Check for wear at the front of the crankshaft flange

 In case of wear on the crankshaft (1); if necessary, rework.

5

Check for cracks and damage to the primary and the connecting rod necks

 In case of damage or cracks:



Replace the crankshaft (1).



Measure

6

Check the hardness of the primary and connecting rod necks of the crankshaft (1)

 Replace the crankshaft in case of hardness lower than prescribed.

*BE03.20-B-1006-02C



*000589202100

If the hardness value is not achieved:



Replace the crankshaft (1).

7

Measure the concentric rotation of the crankshaft (1) using a dial indicator (7) and the dial indicator support (8)

 Place the crankshaft (1) on the external primary neck.

Allowed deviations from the circumference of the primary bearing neck and the connecting rod neck

*BE03.20-B-1015-02C

Permissible axial deviation of the face

*BE03.20-B-1020-02C

Concentricity deviation measured at the intermediate primary bearing neck (support on the outside necks of the primary bearing)

*BE03.20-B-1010-02C

Engine 904

Allowed crankshaft unbalance (with flywheel locking pin, but without the flywheel), fastened to the outside primary bearings.

*BE03.20-B-1017-02C

Engine 902, 906

Allowed crankshaft unbalance (with flywheel locking pin, but without the flywheel), fastened to the primary bearings #2 and #6.

*BE03.20-B-1017-02C



*001589532100



*363589022100

In the case of out-of-tolerance values:



Replace the crankshaft (1).

8

Measure the primary bearing and the connecting rod neck

 Clean the crankshaft (1) bearings with a chamois cloth.

Measure the primary bearing neck - diameter (A) using the outside micrometer (3) at two points (offset by approx 90°).

*BE03.20-B-1001-02C

Bearing neck width (B)

*BE03.20-B-1002-02C

Bearing neck width (C)

*BE03.20-B-1002-02C

Measure the connecting rod neck - diameter (A) using the outside micrometer (3) at two points (offset by approx 90°).

*BE03.20-B-1003-02C

Width of the connecting rod neck (E)

*BE03.20-B-1011-02C

Allowable taper on the neck of the primary bearing and the connecting rod neck

*BE03.20-B-1015-02C

Fillet radius of the neck of the primary bearing and the connecting rod neck (F)

*BE03.20-B-1012-02C

Semi-spherical shape of the main bearing neck and the connecting rod neck (G)

*BE03.20-B-1013-02C

In case of damage or wear:



Rework or replace the crankshaft (1) at the next tolerance deviation.

Storage

9

Radial bearings on the crankshaft (1)

 Clean the crankshaft (1) necks with a chamois cloth.

AR03.20-B-4355-01TB

Diameter of the primary bearing neck (A)

*BE03.20-B-1001-02C

Diameter of the primary internal bearing - diameter as assembled (H)

*BE03.20-B-1007-02C



*BA01.40-B-1001-01B



*001589532100

10

Install the crankshaft (1)

AR03.20-B-4351TA

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-1002-02C

Width

of the main adjustment neck

Normal

mm

31.000...31.100

31.000...31.100

Repair I

mm

31.300...31.400

31.300...31.400

repair II

mm

31.500...31.600

31.500...31.600

of the other main necks

mm

31.0...31.2

31.0...31.2

BE03.20-B-1003-02C

Connecting rod neck diameter in the crankshaft

Normal

mm

69.995...70.015

69.995...70.015

Normal I

mm

69.895...69.915

69.895...69.915

Repair I

mm

69.745...69.765

69.745...69.765

repair II

mm

69.495...69.515

69.495...69.515

repair III

mm

69.245...69.265

69.245...69.265

repair IV

mm

68.995...69.015

68.995...69.015

BE03.20-B-1006-02C

Hardness of the main necks and the connecting rods' necks (Rockwell hardness)

minimum

HRC

52

52

BE03.20-B-1007-02C

Internal diameter of sleeves of the main necks (assembled)

Normal

mm

86.066...86.108

86.066...86.108

Normal I

mm

85.966...86.008

85.966...86.008

Repair I

mm

85.816...85.858

85.816...85.858

repair II

mm

85.566...85.608

85.566...85.608

repair III

mm

85.316...85.358

85.316...85.358

repair IV

mm

85.066...85.108

85.066...85.108

BE03.20-B-1010-02C

Crankshaft eccentricity (supported on the external main necks)

Maximum

mm

0.11

0.15

BE03.20-B-1011-02C

Connecting rod neck width

Normal

mm

34.0...34.2

34.0...34.2

repair

mm

-

-

BE03.20-B-1012-02C

Necks matching radius

main

mm

2.5...3.0

2.5...3.0

connecting rods

mm

2.5...3.0

2.5...3.0

BE03.20-B-1013-02C

Main necks and connecting rods bulging

mm

0...0.004

0...0.004

BE03.20-B-1015-02C

Maximum roundness and taper in the main and connecting rod necks

Limit for reuse

mm

0.02

0.02

new or machined crankshaft

mm

0.005

0.005

BE03.20-B-1017-02C

Maximum dynamic unbalancing.

at 400/min.

Ncm

0.3

0.3

with steering wheel attachment pin, but without the steering wheel), attached onto the main two and six bearings

gcm

30

30

BE03.20-B-1020-02C

Allowed lateral end play

Bearing pin

mm

0.015

0.015

Número

Denominação

Engine 900.9, 902.9, 904.9; 906.9

BA01.40-B-1001-01B

Main bearing cap bolts to engine block

1st stage

Nm

30

2nd stage

Nm

80

3rd stage

Nm

155

4th stage

Degrees

90°