Remove/install crankshaft

AR03.20-D-4351TSV

Remove/install crankshaft

06.03.2020

Engine

642 in model 907

1

Crankshaft

4

Crankshaft bearing cap

7

Thrust plates

2

Crankshaft bearing shells

5

Crankshaft fitted bearing cap

10

Crankcase

3

Crankshaft bearing shells

6

Thrust plates

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Remove pistons with connecting rods.

AR03.10-D-7021TSV

 The connecting rods remain on the pistons.

2

Remove timing case cover.

AR01.40-D-8000TSV

3

Screw in center bolt of crankshaft (1).

4

Determine end play of crankshaft main bearing.

AR03.20-D-4291-03TSV

Crankshaft bearing clearance (when new)

*BE03.20-N-1001-04B

 Dial indicator holder

*363589022100

 Dial gage

*001589322100

If the maximum value of the crankshaft main bearing end play is exceeded,



Replace thrust plates (6, 7) and perform test again.

If the maximum value of the crankshaft main bearing end play is exceeded again,



Replace crankshaft (1), crankshaft bearing shells (2, 3) and crankcase (10).

5

Mark the crankshaft bearing caps (4) and crankshaft fitted bearing cap (5) in relation to the crankcase(10).


The crankshaft bearing caps (4), the crankshaft fitted bearing cap(5), and the crankcase (10) are produced together. Do not interchange.
Engine damage can occur otherwise.

6

Remove screws of the crankshaft bearing caps (4) and the crankshaft fitted bearing cap(5) in reverse order of the tightening procedure.

AR03.20-D-4351-14TSV



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

7

Remove crankshaft bearing caps (4) and crankshaft fitted bearing cap (5).

8

Mark crankshaft bearing shells (3) relative to respective crankshaft bearing caps (4) and crankshaft thrust bearing cap (5).

If crankshaft bearing shells (3) are reused.

9

Mark thrust plates(6) in relation to crankshaft fitted bearing cap (5).

If thrust plates (6) are reused.

10

Remove crankshaft bearing shells (3) from crankshaft bearing caps (4) and crankshaft thrust bearing cap (5).

11

Remove thrust plates(6) from crankshaft fitted bearing cap (5).

12

Remove crankshaft (1) from crankcase (10).

13

Mark crankshaft bearing shells (2) in relation to crankcase (10).

If crankshaft bearing shells (2) are reused.

14

Mark thrust plates (7) in relation to crankcase (10).

If thrust plates (7) are reused.

15

Remove crankshaft bearing shells (2) and thrust plates (7) from crankcase (10).

16

Clean all parts of the crank assembly.


The parts of the crank assembly must be absolutely free of soiling.
Engine damage will occur otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A



Check

17

Check crankshaft (1) in removed state.

If maximum value of crankshaft main bearing end play is not exceeded and/or there is no other damage.

Information on assessing wear of main bearings and main bearing journals

AH03.20-P-1000-02MM

Assign crankshaft bearing shells

AR03.20-D-4360-01TSV

 Commercially available devices/tools
Outside micrometer
Quick calipers for internal measurements

Crankshaft bearing

*BE01.40-N-1001-02P

Crankshaft journal-Ø

*BE03.20-N-1001-02TSV

 Bolt, crankshaft bearing cap to crankcase

*BA03.20-N-1002-01J

 Side bolt, crankcase to crankshaft bearing cap

*BA03.20-N-1003-01J

 Dial gage

*001589532100

18

Check crankshaft bearing shells (2, 3), thrust plates (6, 7) and crankshaft bearing journals for wear and damage.

Depending on the findings,



Replace crankshaft bearing shells (2, 3), thrust plates (6, 7) or crankshaft (1).

19

Check remaining parts of crank assembly for wear and damage.

Depending on the findings,



Replace corresponding parts of crank assembly.



Install

20

Assign new crankshaft bearing shells (2, 3).

If crankshaft bearing shells (2, 3) are replaced.

AR03.20-D-4360-01TSV

21

Wet crankshaft bearing shells (2) and thrust plates (7) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

22.1

Insert new crankshaft bearing shells (2) and new thrust plates (7) in crankcase (10).

If crankshaft bearing shells (2) and thrust plates (7) are replaced.

 The crankshaft bearing shells (2) are equipped with an oil groove with oil hole in contrast to the crankshaft bearing shells (3).
Observe installation positions (arrows) of crankshaft bearing shells (2).

22.2

Insert previously marked crankshaft bearing shells (2) and previously marked thrust plates (7) in the respective marked position in the crankcase (10).

If crankshaft bearing shells (2) and thrust plates (7) are reused.

 The crankshaft bearing shells (2) are equipped with an oil groove with oil hole in contrast to the crankshaft bearing shells (3).
Observe installation positions (arrows) of crankshaft bearing shells (2).

23

Wet crankshaft bearing journals with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

24

Position crankshaft (1) in crankcase(10).

25

Wet crankshaft bearing shells (3) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

26.1

Insert new crankshaft bearing shells(3) in crankshaft bearing caps (4) and crankshaft fitted bearing cap (5).

If crankshaft bearing shells (3) are replaced.

26.2

Insert previously marked crankshaft bearing shells(3) in the respective marked crankshaft bearing cap (4) and the marked crankshaft fitted bearing cap (5).

If crankshaft bearing shells (3) are reused.

27

Wet thrust plates (6) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

28.1

Insert new thrust plates (6) in the crankshaft fitted bearing cap (5).

If thrust plates (6) are replaced.

28.2

Insert previously marked thrust plates (6) at the respectively marked location in the crankshaft fitted bearing cap (5).

If thrust plates (6) are reused.

29

Install crankshaft bearing caps (4) and crankshaft thrust bearing cap (5) relative to respectively marked positions in crankcase (10).


Install crankshaft bearing caps (4) and crankshaft thrust bearing cap (5) at same positions and in same directions as previously.
Engine damage can occur otherwise.

30

Screw in new screws for crankshaft bearing caps (4) and crankshaft fitted bearing cap (5) and tighten.

Tightening procedure for crankshaft bearing caps

AR03.20-D-4351-14TSV



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

 Replace screw/bolts.

 Bolt, crankshaft bearing cap to crankcase

*BA03.20-N-1002-01J

 Side bolt, crankcase to crankshaft bearing cap

*BA03.20-N-1003-01J

31

Rotate crankshaft (1) at center bolt and check unobstructed movement.

If crankshaft (1) is sluggish or getting stuck



Check correct use and seating of the crankshaft bearing shells (2, 3).

AR03.20-D-4360-01TSV

32

Unscrew center bolt of crankshaft (1).

33

Install timing case cover.

AR01.40-D-8000TSV

34

Install pistons with connecting rods.

AR03.10-D-7021TSV

Test and set values for crankcase

Number

Designation

Engine 642 in model 907

BE01.40-N-1001-02P

Crankshaft bearing

Basic bore diameter

-

mm

80,500...80,522

Code number 52

1st stage blue

mm

80,500...80,507

Code number 54

2nd stage yellow

mm

80,507...80,514

Code number 56

3rd stage red

mm

80,514...80,522

Basic bore width at fitted bearing

mm

24,979...25,000

Permissible out-of-roundness and conicity of basic bore

mm

0,02

Check values of crankshaft

Number

Designation

Engine 642 in model 907

BE03.20-N-1001-02TSV

Crankshaft journal-Ø

Nominal Ø

mm

75,940...75,965

Repair stage 1

Blue (B)

mm

75,960...75,965

2nd repair stage

Yellow (G)

mm

75,955...75,960

Repair stage 3

Red (R)

mm

75,950...75,955

Repair stage 4

White (W)

mm

75,945...75,950

Repair stage 5

Violet (V)

mm

75,940...75,945

Test specifications for crankshaft bearing clearance

Number

Designation

Engine 642 in model 907

BE03.20-N-1001-04B

Crankshaft bearing clearance (when new)

Radial measurement when new

mm

0,029...0,056

Radial wear limit

mm

-

Axial measurement when new

mm

0,100...0,254

Axial wear limit

mm

-

 Crankshaft

Number

Designation

Engine 642 in model 907

BA03.20-N-1002-01J

Bolt, crankshaft bearing cap to crankcase

Stage 1

Nm

35

Stage 2

°

95

Stage 3

°

95

 Crankshaft

Number

Designation

Engine 642 in model 907

BA03.20-N-1003-01J

Side bolt, crankcase to crankshaft bearing cap

M10

Stage 1

Nm

53

Stage 2

°

95

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01