Install new crankshaft

AR03.20-S-4291A

Install new crankshaft

24.01.2019

Engine

111.948/978 in model 638

Engine

111.979 in model 901, 902, 903, 904

1

Crankshaft bearing cap

1a

Crankshaft bearing cap (thrust bearing)

2

Screw/bolt, crankshaft bearing cap

3

Bearing shell

4

Thrust plate

5

Crankshaft

6

Bearing shell

7

Thrust plate



Remove

1

Remove engine

Engine 111.948/978 in model 638

AR01.10-S-2400A

Engine 111.979 in models 901.0, 902.0, 903.0, 904.0

AR01.10-D-2400C

2

Remove cylinder head

Engine 111.948/978 in model 638

AR01.30-S-5800A

Engine 111.979 in model 901, 902, 903, 904

AR01.30-D-5800C

3

Remove timing case cover

Engine 111.948/978 in model 638

AR01.40-S-8000A

Engine 111.979 in models 901, 902, 903, 904

AR01.40-D-8000C

4

Remove end cover

Engine 111.948/978 in model 638

AR01.40-S-8913A

Engine 111.979 in models 901, 902, 903, 904

AR01.40-D-8913C

5

Remove pistons

Engine 111.948/978 in model 638

AR03.10-S-7021A

Engine 111.979 in model 901, 902, 903, 904

AR03.10-D-7021C

6

Remove crankshaft bearing caps (1, 1a)

7

Remove bearing shells (3) and thrust plates (4)

8

Remove crankshaft (5) from cylinder crankcase

9

Remove bearing shells (6) and thrust plates (7)



Install

10

Determine crankshaft bearing radial play

Determine crankshaft bearing radial play

AR03.20-S-4291-02A

Topical note

Bearing diagram for crankshaft

Motor 111.948/978 im Typ 638Motor 111.979 im Typ 901, 902, 903, 904

AH03.20-P-4351-01GF

Interference fit of crankshaft bearing cap

Motor 111.948/978 im Typ 638

AH03.20-P-4351-02VA

Main bearing journal Ø

*BE03.20-N-1001-02A

Main bearing play

*BE03.20-N-1007-02A

Base and connecting rod bearing journal

*BE03.20-N-1009-02A

Base and connecting rod bearing journal

*BE03.20-N-1010-02A

 Engine 111.948/978 in model 638Crankshaft bearing cap bolts

*BA03.20-N-1001-01A

 Dial gage

*001589322100

Quick calipers for internal measurements



Outside micrometer

11

Determine crankshaft bearing axial play

Check screws for crankshaft bearing cap.

Topical note

Bearing diagram for crankshaft

Engine 111.948/978 in model 638
Engine 111.979 in model 901, 902, 903, 904

AH03.20-P-4351-01GF

Interference fit of crankshaft bearing cap

Motor 111.948/978 im Typ 638

AH03.20-P-4351-02VA

AR03.20-S-4291-03A

AR03.20-S-4351-03A


Lubricate crankshaft bearing cap screws on thread and bolt head contact surface
tighten from inside outward beginning at the thrust bearing.

Main bearing journal

*BE03.20-N-1003-02A

Main bearing journal

*BE03.20-N-1005-02A

Thrust washers at main bearing journal

*BE03.20-N-1006-02A

Main bearing play

*BE03.20-N-1007-02A

 Engine 111.948/978 in model 638Crankshaft bearing cap bolts

*BA03.20-N-1001-01A

Crankshaft bearing cap bolts

*BE03.20-N-1001-01A

 Dial gage

*001589322100

 Dial indicator holder

*363589022100

 Extension

*366589002105

Quick calipers for internal measurements



Outside micrometer

12

Determine connecting rod bearing radial play

AR03.20-S-4291-04A

Connecting rod journal Ø

*BE03.20-N-1002-02A

Connecting rod journal

*BE03.20-N-1004-02A

Connecting rod bearing play

*BE03.20-N-1008-02A

Base and connecting rod bearing journal

*BE03.20-N-1009-02A

Base and connecting rod bearing journal

*BE03.20-N-1010-02A

 Connecting rod bolt

*BA03.10-N-1001-01A

 Dial gage

*001589322100

Quick calipers for internal measurements



Outside micrometer

13

Install pistons

Engine 111.948/978 in model 638

AR03.10-S-7021A

Engine 111.979 in models 901, 902, 903, 904

AR03.10-D-7021C

14

Install end cover

Engine 111.948/978 in model 638

AR01.40-S-8913A

Engine 111.979 in models 901, 902, 903, 904

AR01.40-D-8913C

15

Install timing case cover

Engine 111.948/978 in model 638

AR01.40-S-8000A

Engine 111.979 in models 901.0, 902.0, 903.0, 904.0

AR01.40-D-8000C

16

Install cylinder head

Engine 111.948/978 in model 638

AR01.30-S-5800A

Engine 111.979 in models 901.0, 902.0, 903.0, 904.0

AR01.30-D-5800C

17

Install engine

Engine 111.948/978 in model 638

AR01.10-S-2400A

Engine 111.979 in models 901, 902, 903, 904

AR01.10-D-2400C

18

Check for leaks

Check values for crankshaft bearing cap bolts

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1001-01A

Crankshaft bearing cap bolts

Thread diameter

M

11

11

Length (L) when new

mm

62,0

62,0

Max. length (L)

mm

63,8

63,8

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1001-02A

Main bearing journal Ø

Standard dimension

mm

57,940...57,965

57,940...57,965

Repair stage 1

mm

57,700...57,715

57,700...57,715

Repair stage 2

mm

57,450...57,465

57,450...57,465

Repair stage 3

mm

57,200...57,215

57,200...57,215

Repair stage 4

mm

56,950...56,965

56,950...56,965

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1002-02A

Connecting rod journal Ø

Standard dimension

mm

47,940...47,965

47,940...47,965

Repair stage 1

mm

47,700...47,715

47,700...47,715

Repair stage 2

mm

47,450...47,465

47,450...47,465

Repair stage 3

mm

47,200...47,215

47,200...47,215

Repair stage 4

mm

46,950...46,964

46,950...46,964

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1003-02A

Main bearing journal

Width

mm

23,958...24,042

23,958...24,042

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1004-02A

Connecting rod journal

Width

mm

27,958...28,042

27,958...28,042

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1005-02A

Main bearing journal

Width at fitted bearing

mm

24,500...24,533

24,500...24,533

Repair stages

mm

24,700...24,733

24,700...24,733

or

mm

24,900...24,933

24,900...24,933

or

mm

25,000...25,033

25,000...25,033

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1006-02A

Thrust washers at main bearing journal

Thickness at fitted bearing

mm

2,15...2,20

2,15...2,20

or

mm

2,25

2,25

or

mm

2,35

2,35

or

mm

2,40

2,40

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1007-02A

Main bearing play

radial

mm

0,030...0,050

0,030...0,050

axial

mm

0,300

0,300

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1008-02A

Connecting rod bearing play

radial

mm

0,020...0,065

0,020...0,065

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1009-02A

Base and connecting rod bearing journal

Permissible deviation in roundness

mm

0,005

0,005

Check values of crankshaft

Number

Designation

Engine 111.948/978

Engine 111.979

BE03.20-N-1010-02A

Base and connecting rod bearing journal

Permissible deviation in cylinder shape

mm

0,010

0,010

 Connecting rod

Number

Designation

Engine 111.948/978

Engine 111.979

BA03.10-N-1001-01A

Connecting rod bolt

Stage 1

Nm

42

42

Stage 2

°

90

90

 Crankshaft

Number

Designation

Engine 111.948/978

BA03.20-N-1001-01A

Crankshaft bearing cap bolts

Stage 1

Nm

55

Stage 2

°

90