4352 - Removal, fitting new bearings to and installation of the crankshaft Engines OM 441-443 LA, EURO I

03-4352 Removing crankshaft, fitting new bearings and installing

Data

Dimensions Crankshaft bearing Crankshaft bearing Width of thrust

journal dia. dia. when installed bearing

Standard 104.000 104.112

103.980 104.066

37.81

37.74

Undersize 0.1 103.900 104.012

103.880 103.966

Undersize 0.25 103.750 103.862

103.730 103.816

38.31

38.24

Undersize 0.5 103.500 103.612

103.480 103.566

Undersize 0.75 103.250 103.362

103.230 103.316

38.81

38.74

Undersize 1.0 103.000 103.112

102.980 103.066

Out-of-roundness of bearing journals max. 0.02

Basic bore dia. for crankshaft bearings in crankcase 111.040

110.970

Axial play of crankshaft (thrust bearings) 0.150 - 0.322

Radial play of crankshaft (thrust bearings) 0.087 - 0.153

Radial play of crankshaft (main bearings) 0.080 - 0.146

Hardness of crankshaft journals over two thirds of circumference Rockwell hardness

HRC 56

Special tools

Removal

1 Unscrew hexagon bolts (9) and take off front housing cover.

2 Mark crankshaft bearing caps and crankshaft bearings to each other in accordance with the sequence.

3 Unscrew all hexagon bolts (1 and 2) and take off bearing caps.

4 Screw in one guide drift (arrows) each at front and rear crankshaft ends and remove crankshaft.

Guide drift 403 589 02 63 00

5 Take bearing shell halves out of the crankcase and match to crankshaft bearing caps.

6 Check parts for signs of wear and damage.

Note

The bearing shells for the crankshaft are supplied ready for installation. No reworking may be performed on these parts. The thrust bearings are supplied oversized for repair purposes. The crankshaft should be re-ground according to the bearing shell width. Maintain axial play of crankshaft.

Fitting new bearings

1 Clean bearing points in crankcase and bearing cap only with chamois leather.

2 Insert bearing shell halves in the correct order into the crankcase and into the crankshaft bearing caps and oil.

Note

The locking lugs (arrow) of the bearing shells must be seated in the slots of the basic bores and crankshaft bearing caps. The oil drillings in the bearing shells and crankcase must be aligned.

3 Insert marked crankshaft bearing caps with bearing shells into the crankcase.

4 Gauge shaft length of vertical crankshaft bearing cap bolts (max. 156 mm for re-use).

5 Gauge shaft length of the side crankshaft bearing cap bolts (max. 86.3 mm for re-use).

6 Tighten vertical crankshaft bearing cap bolts (1) in the following stages.

1st stage 100 Nm

2nd stage 200 Nm

3rd stage 300 to 330 Nm

4th stage 90° to 100° angle of rotation

7 Tighten side crankshaft bearing cap bolts (2) in the following stages.

1st stage 80 to 90 Nm

2nd stage 90° to 100° angle of rotation

8 Set 100 - 160 mm dia. internal measuring instrument and dial gauge with 100 - 125 mm micrometer to the zero size of the crankshaft bearing journals.

Dial gauge 001 589 53 21 00

9 Measure crankshaft bearing bore with internal measuring instrument at three points (vertical and 30° each away from separation point up and down).

Dial gauge 001 589 53 21 00

Note

The figures stated in the table must be maintained.

10 Unscrew crankshaft bearing caps again.

Fitting new bearings and installing

Note

The bearing shell halves with the dark back must be installed at the cap side as they are specially treated for high pressures.

1 Blow out oil galleries in crankcase from the oil pump side with compressed air.

2 Clean crankshaft, bearings and bearing seats with chamois leather. Clean oil galleries of crankshaft with wire brush and blow out with compressed air.

3 Test hardness of crankshaft with hardness tester.

Note

Conversion table is enclosed with the hardness tester.

Hardness tester 000 589 20 21 00

4 Insert bearing shell halves in the correct order into the crankcase and into the crankshaft bearing caps and oil.

Note

The locking lugs (arrow) of the bearing shells must be seated in the slots of the basic bores and crankshaft bearing caps. The oil drillings in the bearing shells and crankcase must be aligned.

5 Insert crankshaft with guide drifts (arrows) into the bearing shells in the crankcase.

Guide drift 403 589 02 63 00

6 Markings (arrows) on camshaft sprocket and crankshaft sprocket must be aligned.

7 Insert marked crankshaft bearing caps (arrows) with bearing shells into the crankcase.

8 Gauge shaft length of the vertical crankshaft bearing cap bolts (1) (max. 156 mm for re-use) and tighten in the following stages.

1st stage 100 Nm

2nd stage 200 Nm

3rd stage 300 to 330 Nm

4th stage 90° to 100° angle of rotation

9 Gauge shaft length of side crankshaft bearing cap bolts (2) (max. 86.3 mm for re-use) and tighten in the following stages:

1st stage 80 to 90 Nm

2nd stage 90° to 100° angle of rotation

10 Attach holder with dial gauge to crankcase and check axial play (0.150 - 0.322 mm) of crankshaft.

Holder 363 589 02 21 00

Dial gauge 001 589 53 21 00