Remove/install crankshaft

AR03.20-B-4351D

Remove/install crankshaft

12.02.16



Remove

1

Remove the engine.

Truck chassis 386.0; 386.3; 388.0

AR01.10-B-2400E

Bus chassis 664.0 664.1; 664.2

AR01.10-B-2400H

2

Remove the front cover with seal.

AR01.40-B-8920A

3

Removing pistons

AR03.10-B-7021D

4

Removing the timing case

AR01.60-B-8200E

5

Removing the oil pump.

AR18.10-B-6020C

6

Unscrew the bolts (6) and remove the main bearing caps (5) and the thrust bearing cap (4).

7

Mark the bearing shells (3 and 3.1) in the order corresponding to their respective caps (4 and 5).

 This procedure will permit, in the case of bearing shell reutilization, the assembly in their respective original position.

8

Install a guide pin in each end of the crankshaft (1).



*403589026300

9

Install a rope around the guide-pins and remove the crankshaft (1).

10

Remove the top bearing shells (2 and 2.1) of the engine block bearings.

 Identify the top bearing shells (2 and 2.1) and their respective housings, for a possible utilization in their original positions.

11

Thoroughly clean all parts



Checking

12

Check the crankshaft (1) and all its components for damages or wear

 In the case of damages or wear in the crankshaft (1), grind the crankshaft.

AR03.20-B-4465A

Width of the connecting rod journals

*BE03.20-B-1004-02B

Maximum length for re-utilization of the counterweight bolts

*BE03.20-B-1026-02B

 Counterweights are only removed from the crankshaft (1) in the case of grinding. The counterweights are to be marked before being removed, and after grinding be installed in their respective locations

13

Check the hardness of the main journals and connecting rod journals.

Utilize a hardness tester.

*BE03.20-B-1025-02B

 Measure in three points offset 120 degrees around the journal.

14

Check the crankshaft (1) for eccentricity.

 Support the crankshaft (1) on the first and last journals.

*BE03.20-B-1013-02B



*001589532100



*363589022100

15

Check the maximum eccentricity of the flywheel housing.

 Support the crankshaft (1) on the first and last journals.

*BE03.20-B-1014-02B



*001589532100



*363589022100

16

Check the bearing shells (2, 2.1, 3 and 3.1) and the respective journals on the crankshaft

AR03.20-B-4341-01C

Diameter of the main journals.

*BE03.20-B-1001-02B

Diameter of the main journal bearing shells (installed).

*BE03.20-B-1005-02B

Diameter of the main bearings (housing of the bearing shells).

*BE01.40-B-1004-02B

17

Check the shank length (L) of the bearing cap bolts (6)

*BE01.40-B-1017-02B



Installing

18

With a chamois, clean the main bearing shell housings on the engine block and on the bearing caps

19

Install the bearing shells (2 and 2.1) in the engine block housing

 Observe that the bearing shell alignment tags (2 and 2.1) seat perfectly in the engine block grooves.

 The bearing shells (2 and 2.1) installed in the engine block are fitted with an oil bore, which must coincide with the bores in the engine block.

20

Clean the oil galleries in the crankshaft (1) with a cylindrical wire brush and compressed air. Next, clean the journals with a chamois



Measuring

21

Install the bolts (6) of the bearing caps (4 and 5) and tighten them in the specified stages and torque.

 Install the bearing caps in the correct order and position. The bearing caps are numbered from the engine front.

 Lightly oil the thread and the head seat face of the bolts (6).



*BA01.40-B-1003-01C

22

Measuring on the main bearings.

Radial clearance.

*BE03.20-B-1019-02B



*001589532100



*363589022100

23

Unscrew the bolts (6) and remove the bearing caps (4 and 5).



Installing

24

Oil the bearing shells.

Utilize engine oil.

25

Carefully install the crankshaft (1) in the engine block.

26

At assembly of crankshaft (1) synchronize the gears (9) and (10).

 The markings “1” and “1-1 must coincide.

27

Measure again the shank length (L) of the bolts (6) of the bearing caps (4 and 5)

*BE01.40-B-1017-02B

28

Install the bearing caps (4 and 5) in the correct order and position.

29

Install the bolts (6) in the determined stages and torque.

 Lightly oil the thread and the head seat face of the bolts (6).



*BA01.40-B-1003-01C

30

Manually turn the crankshaft (1).

 In the case of binding, disassemble the crankshaft (1) and seek the causes.

31

Check the axial clearance of the crankshaft (1)

If necessary, replace the bearing shells (3.1) in the thrust bearing (4).

*BE03.20-B-1018-02B



*363589022100



*001589532100

32

Installing the oil pump.

AR18.10-B-6020C

33

Installing the timing case.

AR01.60-B-8200E

34

Installing the pistons

AR03.10-B-7021D

35

Installing the front cover with seal.

AR01.40-B-8920A

36

Installing the engine.

Truck chassis 386.0; 386.3; 388.0

AR01.10-B-2400E

Bus chassis 664.0; 664.1; 664.2

AR01.10-B-2400H

Número

Denominação

Engine 475.9, 476.9

BE01.40-B-1004-02B

Inner diameter of main bearings

mm

111,000...111,022

BE01.40-B-1017-02B

Maximum bearing bolt reuse length

mm

156

Número

Denominação

Engine 475.9

Engine 476.9

BE03.20-B-1001-02B

Main journals diameter

Normal

mm

103,98...104,00

103,98...104,00

Normal I

mm

103,88...103,90

103,88...103,90

Repair I

mm

103,73...103,75

103,73...103,75

Insert II

mm

103,48...103,50

103,48...103,50

Insert III

mm

103,23...103,25

103,23...103,25

Insert IV

mm

102,98...103,00

102,98...103,00

BE03.20-B-1004-02B

Width of connecting rods

mm

46,000...46,100

46,000...46,100

BE03.20-B-1005-02B

Inner diameter of main bearing shells

Normal

mm

104,014...104,060

104,014...104,060

Normal I

mm

103,914...103,960

103,914...103,960

Repair I

mm

103,764...103,810

103,764...103,810

Insert II

mm

103,514...103,560

103,514...103,560

Insert III

mm

103,264...103,310

103,264...103,310

Insert IV

mm

103,014...103,060

103,014...103,060

BE03.20-B-1013-02B

Shaft maximum eccentricity

0,06

0,09

BE03.20-B-1014-02B

Maximum flywheel housing runout

mm

0,04

0,04

BE03.20-B-1018-02B

Crankshaft radial clearance

mm

0,150...0,322

0,150...0,322

BE03.20-B-1019-02B

Crankshaft radial clearance

Main journals

mm

0,064...0,126

0,064...0,126

Connecting rods

mm

0,060...0,120

0,060...0,120

BE03.20-B-1025-02B

Journal surface hardness

Rc

54...60

54...60

BE03.20-B-1026-02B

Maximum balancing weight bolt reuse length

mm

71,2

71,2

Número

Denominação

Engine 475.9; 476.9

BA01.40-B-1003-01C

Main busing covers bolts

1st stage

Nm

100

2nd stage

Nm

200

3rd stage

Nm

300...330

Angular final tightening

degrees

90...100