Remove/install crankshaft

AR03.20-D-4351WE

Remove/install crankshaft

26.7.11

21.6.11

Special tool for counterholder 651 589 08 40 00 added

AR01.10-D-1000-01WE

21.6.11

Special tool for counterholder 651 589 08 40 00 added

AR05.10-D-7620-01WE



Removing

1

Remove engine and install on assembly stand

AR01.10-D-2401WE

2.1

Remove flywheel

With transmission 711.680

AR03.30-D-8002WE

2.2

Remove driven plate

On model 906 with transmission 722.686

AR03.30-D-8003WE

3

Remove cylinder head cover

AR01.20-D-5014WE

4

Remove cover on cylinder head

AR01.30-D-5701WE

5

Remove timing case cover

AR01.40-D-8000WE

6

Remove oil pan

AR01.45-D-7500WE

7

Remove oil suction pipe (9)

AR18.10-D-4020WE

8

Move engine to basic position and arrest

 The  hold-down device remains on the camshaft and the  assembly tool remains on the Lanchester balance shaft in the crankshaft bearing cap (7).

AR05.10-D-7620-01WE



*BA05.20-N-1002-01O

 Counterholder (with code (H08) High performance A/C or with code (HK4) Rear A/C, enhanced)

*651589004000

 Counterholder (without code (H08) High performance A/C or without code (HK4) Rear A/C, enhanced)

*651589084000

 Holddown device

*651589014000

 Assembly tool

*651589026300

9

Remove belt pulley/vibration damper

AR03.30-D-1600WE

10

Remove bracket together with poly-V belt tensioning device

AR13.25-D-3300WE

11

Remove end cover together with radial shaft sealing ring

AR01.40-D-8920WE

12

Detach connecting rod bearing bolts (14) on connecting rod bearing cap (13)

13

Remove intermediate gear for the engine control

AR05.10-D-7620WE

14

Unscrew bolts (8) in opposite order of tightening torque

AR03.20-D-4351-02WE

15

Remove crankshaft bearing cap (7)

16

Remove bearing shells (5) and fitted bearing shells with thrust plates (6) from crankshaft bearing cap (7).

 Mark bearing shells (5) and fitted bearing shells with thrust plates (6) in relation to corresponding crankshaft bearing.

17

Mark connecting rods (10) in connecting rod bearing cap (13) on one side relative to each other for this step

 If necessary, turn crankshaft (1) 180°. While rotating crankshaft (1) ensure that connecting rods (10) do not get caught.

18

Unscrew connecting rod bearing bolt (14) and remove connecting rod bearing cap (13).

19

Remove connecting rod bearing shells (11, 12)

 Mark upper connecting rod bearing shell (11) and lower connecting rod bearing shell (12) in relation to corresponding connecting rod bearing cap (13). Do not mix up connecting rod bearing shells (11, 12).

20

Take crankshaft (1) out of crankcase (2)

 Aid of helper required.

21

Remove bearing shells (3) and fitted bearing shell with thrust plates (4) from cylinder crankcase (2)

 Mark bearing shells (3) and fitted bearing shells with thrust plates (4) in relation to corresponding crankshaft bearing.



Clean

22

Clean sealing surfaces and bearing surfaces on cylinder crankcase (2) and crankshaft bearing cap (7)

 Do not use sharp-edged or pointed implements to clean. Damage can occur to the sealing and bearing surfaces otherwise.

Cold-sprayable cleaner

*BR00.45-Z-1001-04A



Measure

23

Measure crankshaft (1), mount in bearings

AR03.20-D-4355WE



Checking

24

Check connecting rod bearing bolts (14)

AR03.10-D-6111-01US

*BE03.10-N-1001-03D

25

Check bolts (8) on crankshaft bearing cap (7)

AR03.20-D-4351-03WE

*BE03.20-N-1003-01G



Install

26

Assign bearing shells (3, 5) and fitted bearing shells with thrust plates (4, 6)

 When replacing bearing shells (3, 4)and fitted bearing shells with thrust plates (4, 6) or crankshaft (1).

AR03.20-D-4360-01WE



Bearing diagram for crankshaft

AH03.20-N-4351-01WE

27

Insert bearing shells (3) and fitted bearing shells with thrust plates (4) into cylinder crankcase (2).

 Lubricate bearing shells (3) and fitted bearing shell with thrust plate (4) Observe marking on bearing shells (3).

28

Insert crankshaft (1) in crankcase (2)

 Aid of helper required.

29

Lubricate connecting rod bearing shells (11) and insert into connecting rods (10).

 Insert the connecting rod bearing shells (11) untilted into the connecting rods (10). Connecting rod bearing damage may occur otherwise.

 Observe assignment of connecting rod bearing shells (11) in relation to connecting rods (10).

30

Insert connecting rod bearing shells (12) into connecting rod bearing cap (13)

 Insert connecting rod bearing shells (12) untilted into the connecting rod bearing cap (13). Connecting rod bearing damage may occur otherwise.

 Observe marking on connecting rod bearing shells (12) in relation to connecting rod bearing caps (13).

31

Position connecting rod bearing cap (13) on crankshaft (1) and connecting rod (10) and screw in connecting rod bearing bolts (14)

 Assemble connecting rod bearing cap (13) and connecting rods (10) according to provided markings. Connecting rod bearing cap (13) and connecting rods (10) are cracked (broken) and should not be mixed up or installed with sides mixed up to prevent decreasing dimensional accuracy.

 Tighten connecting rod bearing bolts (14) only to first and second stage tightening torque.



*BA03.10-N-1001-01N

32

Insert bearing shells (5) and fitted bearing shells with thrust plates (6) into crankshaft bearing cap (7).

 Lubricate bearing shells (5) and fitted bearing shell with thrust plate (6) Observe marking on bearing shells (5).

33

Install crankshaft bearing cap (7) with arrested Lanchester balance shafts on cylinder crankcase (2)

 Ensure that fitted sleeve is seated correctly.

34

Tighten bolts (8) according to tightening procedure of crankshaft bearing cap (7)

 Lubricate bolts (8) on thread and bolt head contact surface.

AR03.20-D-4351-02WE



*BA03.20-N-1001-01J

35

Tighten connecting rod bearing bolts (14) of connecting rod cap(13) to third stage tightening torque

AR03.10-S-6111-02SD



*BA03.10-N-1001-01N

36

Install end cover together with radial shaft sealing ring

AR01.40-D-8920WE

37

Install carrier with poly-V belt tensioning device

AR13.25-D-3300WE

38

Install belt pulley/vibration damper

AR03.30-D-1600WE

39

Turn crankshaft (1) with counterholder to top dead center position on 1st cylinder

AR01.10-D-1000-01WE

 Counterholder (with code (H08) High performance A/C or with code (HK4) Rear A/C, enhanced)

*651589004000

 Counterholder (without code (H08) High performance A/C or without code (HK4) Rear A/C, enhanced)

*651589084000

40

Install intermediate gear on engine timing

AR05.10-D-7620WE

41

Install oil suction pipe (9)

AR18.10-D-4020WE

42

Install oil pan

AR01.45-D-7500WE

43

Install timing case cover

AR01.40-D-8000WE

44

Install cover on cylinder head

AR01.30-D-5701WE

45

Install cylinder head cover

AR01.20-D-5014WE

46.1

Install flywheel

With transmission 711.680

AR03.30-D-8002WE

46.2

Install drive plate

On model 906 with transmission 722.686

AR03.30-D-8003WE

47

Remove engine from assembly stand and install in vehicle

AR01.10-D-2401WE

Number

Designation

Engine
651
in models 639, 900, 906

BE03.10-N-1001-03D

Connecting rod bolt

Thread diameter

M

81

Shank length

New

mm

47 (0.3)

max.

mm

48

Number

Designation

Engine
651 in models
639, 900, 906

BE03.20-N-1003-01G

Crankshaft bearing cap bolts M12

Thread diameter

M

12

Length (L) when new

mm

104.7 to 105.3

Max. length (L)

mm

106.5

See picture

AR03.20-P-4351-03A

Number

Designation

Engine 651 in model 900

Engine 651 in model 639, 906

BA03.10-N-1001-01N

Bolt, connecting rod bearing cap to connecting rod

At initial tightening torque
after cracking

Stage 1

Nm

5

5

Stage 2

Nm

25

25

Stage 3

°

180

180

For subsequent tightening

Stage 1

Nm

5

5

Stage 2

Nm

25

25

Stage 3

°

90

90

Number

Designation

Engine
651 in model 900

Engine 651
in model 639, 906

BA03.20-N-1001-01J

Bolt for crankshaft bearing cap

M11

Stage 1

Nm

-

-

Stage 2

°

-

-

M12

Stage 1

Nm

60

60

Stage 2

°

90

90

Number

Designation

Engine
651 in model 900

Engine
651 in model 639, 906

BA05.20-N-1002-01O

Bolt connecting camshaft bearing cap to cylinder head

Nm

9

9

Number

Designation

Order number

BR00.45-Z-1001-04A

Cold-sprayable cleaner

Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munich
Germany
Tel. +49-89-9268-0
Fax + 49-89-9101978
www.Loctite.de