4352 - Removal of the crankshaft, mounting in bearings and installation Engines OM 364, 366, 366 A/LA, EURO I

03-4352 Removing crankshaft, mounting in bearings and installing

Data "A" crankshaft

Axial clearance of crankshaft Fitted bearing 0.190 to 0.290

Conrod bearing 0.100 to 0.400

Radial clearance of crankshaft Main bearing 0.042 to 0.108

Fitted bearing 0.050 to 0.108

Conrod bearing 0.041 to 0.100

Permissible out-of-roundness of main Limit 0.01

and conrod bearing journals

Permissible conicity Main bearing journal 0.01

Conrod bearing journal 0.005

Permissible lateral runout Crankpin 0.02

Fillet radii Main bearing journal 3.5 to 4.0

Fitted bearing 4.0 to 4.5

Hardness of crankshaft and conrod bearing journals (Rockwell hardness) 53 to 59 HRC

after damage to bearings and in the case of severe bearing wear,

over two thirds of the circumference min. 46 HRC

Data "A" crankshaft

Permissible imbalance 30 cmp

Camber Main bearing journal 0 to 0.004

Conrod bearing journal 0 to 0.04

for rep. max.

Data "B" (Main bearing and fitted bearing)

Data "C" (Conrod bearing shells)

Special tools

Note

The previous locating plate part no. 352 589 01 31 00 can be returned for conversion to:

Ludwig Weyland GmbH

Lotschstr. 11

76829 Landau

Removing

1 Unscrew main bearing bolts (19).

2 Slacken crankshaft bearing cap (18, 20) with a plastic hammer and remove.

Note

The crankshaft bearing caps and the bearing shells of the main bearings must be marked in accordance with the fitting order in order to avoid mix-ups.

3 On divided timing case:

3.1 Dismantle and remove lower section of timing case (4a).

4 On one-piece timing case:

4.1 Remove kidney-shaped cover (2) on timing case and remove gasket (3).

4.2 Crank engine in direction of rotation until the marking of the camshaft and crankshaft are aligned.

Note

The tooth of the crankshaft gear marked with "1" must be located between the teeth of the injection timer which are also marked with "1-1".

4.3 Mark injection pump gear relative to timing case.

4.4 Remove injection pump (07-8410). Remove O-ring.

4.5 Unscrew securing bolt (10) for injection timer (11).

4.6 Pull off injection timer (11) and parallel key (13).

4.7 Remove shim (12) and thrust washer (8) for camshaft.

4.8 Remove timing case (4). Remove gasket (6).

5 Lift crankshaft (14) out of crankcase.

Note

On flywheel housing which is closed underneath:

Remove flywheel (03-8001) and remove flywheel housing (23).

6 Take main bearing shells (16, 17) out of the crankcase and out of the main bearing caps and mark.

7 Remove fabric seal (22) and locking pin (21) from crankcase and crankshaft bearing cap (20).

8 Check all parts for wear and tear.

Bearings

Note

The main bearing shells of the crankshaft are factory-supplied ready for installation. It is not permitted to perform any machining work on the bearing shells.

1 Use a shammy leather to clean the bearing points in the crankcase and in the crankshaft bearing caps.

2 Measure bearing journals of the crankshaft. See data "A" for dimensions.

3 Insert bearing shells into the crankcase and into the crankshaft bearing caps in the correct order. Ensure that the locking lugs of the bearing shells are properly located in the slots and in the basic bores.

Note

The main bearing shells in the crankcase are provided with an oil bore and must be aligned with the lubricating bore in the crankcase (arrows).

4 Fit crankshaft bearing caps (18, 20) onto the crankcase. Pay attention to the marking.

Note

- Fit the crankshaft bearing cap with cylindrical or tapered dowel pin. The two versions of the dowel pin must not be mixed up.

- Replace the tapered dowel pins (18a) only in pairs. Install new dowel pins (18a) with the cylindrical half in the crankshaft bearing caps. Projection dimension "A": 9.5 mm.

5 Tighten main bearing bolts (19),

1st stage 80 to 90 Nm,

2nd stage 90° to 100° angle of rotation.

6 Attach dial gauge to hole gauge. Set 50 - 100 mm diameter hole gauge with 75 - 100 mm diameter micrometer to the zero size of the main bearing bore.

Dial gauge 001 589 53 21 00

7 Measure main bearing bore with the set 50 - 100 mm dia. hole gauge at three points (vertical and at about 30° above and below the separation points).

Note

The measurements must conform to the figures stated in data "B".

8 Remove crankshaft bearing caps (18, 20) again and remove the fitted and main bearing shells from the crankcase.

Bearings and installation

1 Use a wire brush to clean the oil galleries of the crankshaft (14) and blow out.

2 Blow out oil galleries from the oil pump end.

3 Use a chamois leather to clean crankshaft bearing journals, main bearing shells and bearing seats.

4 Check the crankshaft and conrod bearing journals with a hardness drop tester. See data "A" for hardness.

Note

A conversion table is enclosed with the hardness drop tester.

Hardness drop tester 000 589 20 21 00

5 Use an aluminium drift to insert locking pin (21) in the crankcase and in the crankshaft bearing cap (20).

Note

Tip of locking pin faces out of the hole and must not be damaged.

6 Insert new fabric seal (22) exactly into the locating plate.

Note

Both ends of the fabric seal (22) must be making contact with the locating plate.

Locating plate 352 589 02 31 00

7 Fit on locating plate and press fabric seal into the crankcase. Remove locating plate.

Locating plate 352 589 02 31 00

8 Cutting fabric seal to the correct length

Note

- The projection (overlap) of 0.8 to 1.1. mm is distributed half each to the crankcase and to the crankshaft bearing cap.

- After installing the crankshaft bearing cap, there must be an overlap of the two fabric seals of 0.8 to 1.1 mm.

8.1 To ensure that an exact overlap is achieved, select an appropriate valve gauge and fit onto the crankcase as a spacer gauge.

8.2 Make cuts in the fabric seal at 3 sides (arrows), before finally cutting to length to prevent it fraying when it is finally cut to length.

8.3 Start cutting off fabric seal with a sharp knife at the end which has not yet been cut.

9 Insert new, second fabric seal (22) into the locating plate. Mount locating plate on the crankshaft bearing cap and press in fabric seal (22). Remove locating plate.

Locating plate 352 589 02 31 00

10 Cutting fabric seal to correct length.

Note

- The projection (overlap) of 0.8 to 1.1 mm is distributed half each to the crankcase and to the crankshaft bearing cap.

- After installing the crankshaft bearing cap, there must be an overlap of the two fabric seals of 0.8 to 1.1 mm.

10.1 To ensure that an exact overlap is achieved, select an appropriate valve gauge and fit onto the crankcase as a spacer gauge.

10.2 Make cuts in the fabric seal at 3 sides (arrows), before finally cutting to length to prevent it fraying when it is finally cut to length.

10.3 Start cutting off fabric seal with a sharp knife at the end which has not yet been cut.

11 Coat fabric seals (22) in crankcase and in the crankshaft bearing cap (20) with hot bearing grease.

12 Install crankshaft bearing cap with fabric seal as a check and tighten bolt to 90 Nm (initial torque).

13 Remove crankshaft bearing cap again and check fabric seals at the joint for loose or compressed fibers; cut off with a sharp knife, if necessary.

14 Insert main bearing shells into the crankcase and into the crankshaft bearing caps in the correct order. Ensure that the locking lugs of the main bearing shells are properly located in the slots and in the basic bores.

Note

The main bearing shells in the housing are provided with an oil bore and must be aligned with the lubricating bore in the crankcase (arrows).

15 Coat slot and contact surface at the rear crankshaft bearing cap (20) with Dirko Transparent sealant.

Note

- The surfaces to be coated with the sealant must be free of grease.

- The contact surfaces of the fabric seals must not be coated with sealant.

16 Oil contact surface of the main bearing shells with engine oil.

17 Insert crankshaft (14) into the main bearing shells.

Note

On the divided timing case ensure that the tooth of the crankshaft gear marked with "1" is located between the teeth of the injection timer which is also marked with "1-1".

18 Measure length of shank of the main bearing bolts (19).

Note

The main bearing bolts (19) may be re-used up to a maximum shank length of 123.0 mm.

19 Fit on crankshaft bearing caps (18, 20) with bearing shells. Ensure that the markings of the bearings that go with them are aligned.

Note

- Fit crankshaft bearing cap with cylindrical or tapered dowel pins.

The two versions of the dowel pins must not be mixed up.

- Replace tapered dowel pins (18a) in the crankshaft bearing caps only as a pair. Install new dowel pins (18a) with the cylindrical half into the crankshaft bearing caps, projection dimension "A" 9.5 mm.

20 Tighten main bearing bolts (19),

1st stage 80 to 90 Nm,

2nd stage 90° to 100° angle of rotation.

21 Attach dial gauge and gauge stand to timing case or crankcase. Measure axial clearance of crankshaft (fitted bearings) 0.190 to 0.290 mm.

Dial gauge 001 589 53 21 00

Gauge stand 363 589 02 21 00

22 On divided timing case:

22.1 Coat contact surfaces of lower section of timing case (4a) with Curil T sealant.

22.2 Coat hexagon bolt M840 (4b) on thread with Hylomar SQ 32M sealant.

22.3 Screw on lower section of timing case with hexagon bolts M840 (4b) and M822 (4c) to timing case.

23 On one-piece timing case

23.1 Fit timing case (4) with new gasket (6) onto crankcase.

Note

- Coat engine end of gasket (6) with Curil T sealant.

- Identification of adapter (5):

OM 364 "4"; OM 366 "6".

23.2 Install new one-piece adapter (5) in timing case (4) (oil return of belt-driven air compressor).

23.3 Tighten hexagon bolts (7) to 60 Nm.

23.4 Install thrust washer (8) for camshaft. Tighten hexagon bolts (9) to 35 Nm.

23.5 Slide on shim (12).

23.6 Install injection timer (11) and parallel key (13).

Note

- Backlash 0.070 to 0.180 mm.

- The tooth of the crankshaft gear marked with "1" must be located between the teeth of the injection timer which is also marked with "1-1". The markings must be in line with the center of the two gears.

23.7 Tighten securing bolt (10), 300 Nm.

23.8 Install injection pump (07-8410). Install new O-ring. Tighten hexagon bolt to 45 Nm.

Note

The marking of the injection pump gear points toward the marking on the timing case.

23.9 Check start of delivery and adjust (07-8234).

23.10 Install kidney-shaped cover (2) with new gasket. Coat hexagon bolts (1) with Hylomar SQ 32M sealant and tighten.

24 Installing flywheel housing (closed version)

24.1 Install flywheel (03-8001).