Remove/install crankshaft

AR03.20-T-4351BB

Remove/install crankshaft

12.12.08



Removing

1.1

Remove engine

Model 613.358/388

AR01.10-T-2400BA

1.2

Remove engine with transmission

Model 671.015/020/ 021/030/ 332/333

Model 671.042

AR01.10-T-2401AA

 Model 671: disconnect mechanism from engine. Attach engine on a suitable assembly stand in such a way that the timing case is exposed.

2.1

Remove alternator support

Model 613.358/388

AR15.40-T-6232BA

3

Remove belt pulley, vibration damper

Model 613.358/388

AR03.30-T-1600BA

Model 671.015/020/021/030/042/332/333

AR03.30-T-1600AA

4

Remove pistons

AR03.10-T-7021BB

5

Remove starter

Model 613.358/388

AR15.30-T-7100BA

Model 671.015/020/021/030/042/332/333

AR15.30-T-7100AA

6

Remove flywheel

AR03.30-T-8002BB

7

Remove oil pressure relief valve

AR18.10-T-5031BB

8

Remove oil pump

Model 613.358/388

AR18.10-T-6020BA

Model 671.015/020/021/030/042/332/333

AR18.10-T-6020AA

9

Remove end cover together with radial shaft sealing ring

AR01.40-T-8920BB

10

Remove timing case

AR01.60-T-8200BB

11

Remove bearing cap (6), fitted bearing cap (7) with bearing shells (4) and fitted bearing shell (5)

 Place match marks for associated bearing shells and bearing cap .

12

Remove crankshaft (1)

 Screw a guide drift into each of the crankshaft ends. Lift crankshaft out of crankcase carefully (for example using a hemp rope and a suitable lifting device).



*403589026300

13

Remove bearing shells (2) and fitted bearing shell (3)

 Place match marks for bearing shell (2), fitted bearing shell (3) and associated bearing seats in cylinder crankcase.

14

Clean all parts.

 Clean crankshaft, crankshaft bearing and bearing seats using a chamois leather, blow out oil ducts on cylinder crankcase (from the oil pump side) and crankshaft oil ducts using compressed air.



Checking

15

Measure crankshaft (1), mount in bearings

AR03.20-T-4355BB

16

Check shank length (L) of bolts (8).

If permissible shank length (L) of bolts (8) is exceeded, replace them.

*BE01.40-N-1004-02I



Install

17

Insert bearing shells (2) and fitted bearing shell (3)

 Lubricate contact surfaces slightly. Pay attention to applied markings in the case of used bearing shells. Insert fitted bearing shell (3) in the fourth main bearing. The locking lugs for bearing shells (2) and fitted bearing shell (3) must fit in the grooves of basic bores of the crankcase (arrows).

Oil holes in bearing shells (2), the fitted bearing shell (3) and crankcase must match.

18

Insert bearing shells (4) in bearing cap (6) and fitted bearing cap (5) in fitted bearing cap (7)

 Lubricate contact surfaces slightly. In the case of worn bearing shells (4) and fitted bearing shell (5) observe markings. The fit bearing shells (5) must be inserted into the fourth main bearing.

The locking lugs for bearing shells (4) and the fitted bearing shell (5) must fit in grooves of the bearing caps (arrows).

19

Lubricate crankshaft bearing journal and install crankshaft (1)

Screw in one drift per crankshaft end. Insert crankshaft (1) into crankcase carefully (for example with a hemp rope and a suitable lifting device).

The marked teeth on the cam (11) and crankshaft gear (12) must coincide.



*403589026300

20

Insert bearing caps (6) and fitted bearing caps (7), apply pressure by hand and bolt tightly

 Observe any markings. The bearing caps are numbered in ascending order beginning on the side of the vibration damper.

Pay attention to position of guide studs.

 Lightly oil the bolts (8) on thread and on contact surface of the screw head.



*BA01.40-N-1004-01L

21

Check crankshaft for light running

 Rotate crankshaft by hand. In the case of sluggishness loosen bolts for individual bearing caps one after the other in order to localize the sluggish crankshaft bearing.

22

Determine crankshaft axial play

AR03.20-T-4341-02B

*BE03.20-N-1012-02J



*001589532100



*363589022100

23

Install timing case

AR01.60-T-8200BB

24

Install end cover together with radial shaft sealing ring

AR01.40-T-8920BB

25

Install oil pump

Model 613.358/388

AR18.10-T-6020BA

Model 671.015/020/021/030/042/332/333

AR18.10-T-6020AA

26

Install oil pressure relief valve

AR18.10-T-5031BB

27

Install flywheel

AR03.30-T-8002BB

28

Install starter

Model 613.358/388

AR15.30-T-7100BA

Model 671.015/020/021/030/042/332/333

AR15.30-T-7100AA

29

Install pistons

AR03.10-T-7021BB

30

Install belt pulley, vibration damper

Model 613.358/388

AR03.30-T-1600BA

Model 671.015/020/021/030/042/332/333

AR03.30-T-1600AA

31.1

Install alternator support

Model 613.358 / 388

AR15.40-T-6232BA

31.2

Attach the transmission to the engine.

Model 671

32.1

Install engine

Model 613.358/388

AR01.10-T-2400BA

32.2

Install engine with transmission

Model 671.015/020/ 021/030/ 332/333

Model 671.042

AR01.10-T-2401AA

Number

Designation

Engine 457.9

BE01.40-N-1004-02I

Bolts for crankshaft bearing caps

Thread dia.

M

182

Shank length (L) when new

mm

152.5 to 153.0

permissible shank length (L)

mm

156

Number

Designation

Engine
457.941/942/944

BE03.20-N-1012-02J

Axial play

mm

0.230 to 0.370

Number

Designation

Engine
457.9

BA01.40-N-1004-01L

Bolt, crankshaft bearing cap to crankcase

Stage 1

Nm

300

Stage 2

°

90