Remove/install crankshaft

AR03.20-W-4351C

Remove/install crankshaft

10.11.2015

Engine

457.9 in model 374, 375, 940, 942, 943, 944, 958

Modification notes

22.05.2015

Factual information: oil holes in the crankcase on the outer recumbent main bearings to the bearing shells altered.

Operation step 24

1

Crankshaft

2

Bearing shell

3

Main fitted bearing shell

4

Bearing shell

5

Main fitted bearing shell

6

Crankshaft bearing cap

7

Main fitted bearing cap

8

Screw/bolt

L

Shank length

1

Crankshaft

5

Main fitted bearing shell

9

Crankshaft gear

2

Bearing shell

6

Crankshaft bearing cap

10

Camshaft sprocket

3

Main fitted bearing shell

7

Main fitted bearing cap

11

Drift

4

Bearing shell

8

Screw/bolt

Pfeil A

Marking points

2

Bearing shell

Pfeil B

Oil hole



Remove

1.1

Remove engine

If removal of the engine is due to accessibility and the body is the simplest method.

AR01.10-W-2400E

1.2

Remove engine with transmission

If removal of the engine with transmission is due to accessibility and the body is the simplest method.

MODEL 374, 375, 944, 958

AR01.10-W-2401C

 MODEL 940, 942, 943
Work instructions have not yet been compiled for these models.

2

Remove timing case

Engine 457.9## ## up to 036947 in model 375, 944

AR01.60-W-8200C

Engine 457.9 in model 374, 940, 942, 943, 958
Engine 457.9## ## as of 036948 in model 375, 944

AR01.60-W-8200CA

3

Remove oil pump

AR18.10-W-6020C

4

Remove front housing cover

AR01.40-W-8800C

5

Remove pistons

AR03.10-W-7021C

6

Check markings on the crankshaft bearing caps (6) and the main fitted bearing cap (7)

 Existing markings, e.g. 1x xxx.

If there are no markings.



The crankshaft bearing cap (6) and the main fitted bearing cap (7) are to be marked with numbers, beginning at the front, ascending.

7

Remove main fitted bearing cap (6) and crankshaft fitted bearing cap (7)

8

Remove bearing shells (4) from the crankshaft bearing caps (6) and mark relative to the respective crankshaft bearing caps (6)

9

Remove main fitted bearing shell (5) from main fitted bearing cap (7)

10

Screw drifts (11) into crankshaft (1) at front and rear and secure on shackle

 Drift

*403589026300

11

Lift crankshaft (1) at the shackle out of crankcase and to set it down

12

Remove bearing shells (2) from the crankcase and mark relative to the respective main bearing in crankcase

13

Remove main fitted bearing shell (3) from the crankcase

14

Clean crankshaft (1) and oil duct in crankshaft (1)



Check

15

Visually inspect crankshaft (1) for damage and cracks

In case of a complaint



Replace crankshaft (1).

16

Clean main bearing shells (2, 4), main fitted bearing shells (3, 5) as well as main bearing journals for crankshaft (1) using a chamois leather and check by means of visual inspection



Information on assessing wear of main bearings and main bearing journals

AH03.20-N-1000-02A

In case of a complaint



Repair engine or replace it.

17

Measure concentricity of crankshaft (1) at middle main bearing journal

AR03.20-W-4351-08C

Variation in concentricity measured at middle main fitted bearing journal (mounted at outer main bearing journals)

*BE03.20-N-1011-02M

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

18

Check hardness of main bearing and connecting rod journals

AR03.20-W-4351-09C

Hardness of main bearing and connecting rod journals (Rockwell hardness)

*BE03.20-N-1009-02M

 Hardness tester

*000589202100

19

Determine crankshaft bearing radial play

AR03.20-W-4291-02C

Bolt, crankshaft bearing cap

*BE01.40-N-1001-02N

Main bearing journal Ø, main bearing journal width (except main bearing fitted bearing journal)

*BE03.20-N-1003-02M

Main bearing journal dia. fitted bearing journal width

*BE03.20-N-1004-02M

Main bearing shell inside dia. (except main bearing fitted bearing journal)

*BE03.20-N-1005-02M

Main bearing-fitted bearing shell inside dia. Fitted bearing shell width

*BE03.20-N-1006-02M

Main bearing radial play

*BE03.20-N-1008-02M

 Bolt, crankshaft bearing cap to crankcase

*BA01.40-N-1004-01U

 Dial gage

*001589532100

20

Determine connecting rod bearing radial play

AR03.20-W-4291-04C

Screw/bolt, connecting rod bearing cap to connecting rod

*BE03.10-N-1001-01P

Connecting rod bearing radial play

*BE03.10-N-1002-01P

Connecting rod journal Ø connecting rod journal width

*BE03.20-N-1001-02M

Connecting rod bearing inside dia. with connecting rod bearing shells inserted

*BE03.20-N-1002-02M

 Bolt, connecting rod bearing cap to connecting rod

*BA03.10-N-1001-01L

 Dial gage

*001589532100

 Socket wrench bit

*422589020900

21

Mount crankshaft (1) axially

AR03.20-W-4355-02C

 The main fitted bearing cap (7) is installed.

Main bearing journal dia. fitted bearing journal width

*BE03.20-N-1004-02M

Main bearing-fitted bearing shell inside dia. Fitted bearing shell width

*BE03.20-N-1006-02M

Main bearing axial play

*BE03.20-N-1007-02M

 Dial gage

*001589532100

22

Measure shank length (L) of screw/bolts (8)

Bolt, crankshaft bearing cap

*BE01.40-N-1001-02N

If permissible shank length (L) is exceeded.



Replace with an appropriate screw/bolt (8).



Install

23

Remove metal dust from the internal components

Only if bearing damage has occurred.

 Remove potential metal dust from oil ducts and clean internal components.

24

Lay bearing shells (2) and main fitted bearing shell (3) with groove in the crankcase


An the outer recumbent main bearings 1, 2 and 6, 7 the oil holes (arrows B) in the crankcase are covered up to 1/4 by the bearing shells (2).
On the inner main bearings 3, 4, 5 the oil holes in the crankcase must coincide with the oil holes of the bearing shells (2) and the main fitted bearing shell (3).
A bearing damage can otherwise occur.

 Observe marking of bearing shells (2) relative to crankcase. Lubricate contact surfaces of bearing shells (2) and main fitted bearing shell (3) using engine oil.

25

Place crankshaft (1) with shackle on bearing shells (2) and main fitted bearing shell (3) in the crankcase

 The marking points (arrow A) on crankshaft gear (9) and camshaft sprocket (10) must be positioned opposite to each other.

If the marking points (arrow A) do not stand opposite to each other



Screw a screw/bolt into one of the threaded holes in the crankshaft (1) and turn crankshaft (1) using a suitable lever. Then unscrew screw/bolt again.

 Drift

*403589026300

26

Remove drift (11) and shackle from crankshaft (1)

 Drift

*403589026300

27

Insert main bearing shells (4) from main bearing caps (6) and main fitted bearing shell (5) into main fitted bearing cap (7)

 Observe identification of bearing caps (4) relative to the differential assembly (6). The retaining lug on the bearing shells (4) and the main fitted bearing shell (5) must be fitted in the planned groove.
Lubricate contact surfaces of bearing shells (4) and main fitted bearing shell (5) using engine oil.

28

Install main fitted bearing cap (7) with inserted main fitted bearing shell (5) and main bearing cap (6) with inserted main bearing shells (4)

 The main fitted bearing cap (7) and main bearing cap (6) are marked with numbers and must be installed according to the numbers (e.g. 1x xxx), beginning at the front, ascending.
Note dowel pins.

29

Tighten screw/bolts (8)

Tightening procedure

AR03.20-W-4351-02C

 Observe tightening procedure.

Bolt, crankshaft bearing cap

*BE01.40-N-1001-02N

 Bolt, crankshaft bearing cap to crankcase

*BA01.40-N-1004-01U

30

Rotate crankshaft (1) by hand and check for unobstructed movement

If there is inadequate unrestricted travel



Measure crankshaft bearing radial play and axial play again.

31

Determine crankshaft end play (1)

AR03.20-W-4291-03C

Main bearing axial play

*BE03.20-N-1007-02M

 Dial gage

*001589532100

 Dial indicator holder

*363589022100

If the permissible crankshaft bearing axial play is exceeded.



Check width of the main fitted bearing shell (5).

Main bearing-fitted bearing shell inside dia. Fitted bearing shell width

*BE03.20-N-1006-02M

32

Perform additional checks in case of engine repair work on the crankshaft (1)

AR03.20-W-0002A

33

Install pistons

AR03.10-W-7021C

34

Install front housing cover

AR01.40-W-8800C

35

Install oil pump

AR18.10-W-6020C

36

Install timing case

Engine 457.9## ## up to 036947 in model 375, 944

AR01.60-W-8200C

Engine 457.9 in model 374, 940, 942, 943, 958
Engine 457.9## ## as of 036948 in model 375, 944

AR01.60-W-8200CA

37.1

Install engine

If engine is removed.

AR01.10-W-2400E

37.2

Install engine with transmission

If engine was removed with transmission.

MODEL 374, 375, 944, 958

AR01.10-W-2401C

 MODEL 940, 942, 943
Work instructions have not yet been compiled for these models.

Check values for cylinder crankcase

Number

Designation

ENGINE 457.9

BE01.40-N-1001-02N

Bolt, crankshaft bearing cap

Thread diameter

M

18x2

Length of shank when new

mm

152,5...153,0

Permissible shank length

mm

156

Check values for connecting rods

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4 EURO IV standard, ENGINE 457.9 with CODE MS5 EURO V standard

BE03.10-N-1001-01P

Screw/bolt, connecting rod bearing cap to connecting rod

Thread diameter

M

161,5

161,5

Length of shank when new

mm

67,2...67,5

67,2...67,5

Permissible shank length

mm

68,5

68,5

Check values for connecting rods

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4 EURO IV standard, ENGINE 457.9 with CODE MS5 EURO V standard

BE03.10-N-1002-01P

Connecting rod bearing radial play

mm

0,060...0,120

0,060...0,120

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1001-02M

Connecting rod journal Ø connecting rod journal width

Ø standard width

mm mm

89,980...90,000 46,000...46,100

93,980...94,000 44,500...44,600

Ø Deviation 0.10 width

mm mm

89,880...89,900 46,000...46,100

93,880...93,900 44,500...44,600

Ø Deviation 0.25 width

mm mm

89,730...89,750 46,000...46,400

93,730...93,750 44,800...44,900

Ø Deviation 0.50 width

mm mm

89,480...89,500 46,000...46,400

93,480...93,500 44,800...44,900

Ø Deviation 0.75 width

mm mm

89,230...89,250 46,000...46,400

93,230...93,250 44,800...44,900

Ø Deviation 1.00 width

mm mm

88,980...89,000 46,000...46,400

92,980...93,000 44,800...44,900

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1002-02M

Connecting rod bearing inside dia. with connecting rod bearing shells inserted

Default

mm

90,060...90,102

94,064...94,110

Deviation 0.10

mm

89,960...90,002

93,964...94,010

Deviation 0.25

mm

89,810...89,852

93,814...93,860

Deviation 0.50

mm

89,560...89,602

93,564...93,610

Deviation 0.75

mm

89,310...89,352

93,314...93,360

Deviation 1.00

mm

89,060...89,102

93,064...93,110

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1003-02M

Main bearing journal Ø, main bearing journal width (except main bearing fitted bearing journal)

Ø standard width

mm mm

103,980...104,000 46,000...46,250

103,980...104,000 46,000...46,250

Ø Deviation 0.10 width

mm mm

103,880...103,900 46,000...46,250

103,880...103,900 46,000...46,250

Ø Deviation 0.25 width

mm mm

103,730...103,750 46,000...46,750

103,730...103,750 46,500...46,750

Ø Deviation 0.50 width

mm mm

103,480...103,500 46,000...46,750

103,480...103,500 46,500...46,750

Ø Deviation 0.75 width

mm mm

103,230...103,250 46,000...46,750

103,230...103,250 47,000...47,250

Ø Deviation 1.00 width

mm mm

102,980...103,000 46,000...46,750

102,980...103,000 47,000...47,250

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1004-02M

Main bearing journal dia. fitted bearing journal width

Ø standard width standard

mm mm

103,980...104,000 46,000...46,062

103,980...104,000 46,000...46,062

Ø Deviation 0.10 width standard

mm mm

103,880...103,900 46,000...46,062

103,880...103,900 46,000...46,062

Ø Deviation 0.25 width deviation 0.50

mm mm

103,730...103,750 46,500...46,562

103,730...103,750 46,500...46,562

Ø Deviation 0.50 width deviation 0.50

mm mm

103,480...103,500 46,500...46,562

103,480...103,500 46,500...46,562

Ø Deviation 0.75 width deviation 1.00

mm mm

103,230...103,250 47,000...47,062

103,230...103,250 47,000...47,062

Ø Deviation 1.00 width deviation 1.00

mm mm

102,980...103,000 47,000...47,062

102,980...103,000 47,000...47,062

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1005-02M

Main bearing shell inside dia. (except main bearing fitted bearing journal)

Default

mm

104,060...104,106

104,060...104,106

Deviation 0.10

mm

103,960...103,006

103,960...104,006

Deviation 0.25

mm

103,810...103,856

103,810...103,856

Deviation 0.50

mm

103,560...103,606

103,560...103,606

Deviation 0.75

mm

103,310...103,356

103,310...103,356

Deviation 1.00

mm

103,060...103,106

103,060...103,106

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1006-02M

Main bearing-fitted bearing shell inside dia. Fitted bearing shell width

Ø standard width standard

mm

104,060...104,106 45,74...45,81

104,060...104,106 45,74...45,81

Ø Deviation 0.10 width standard

mm

103,960...103,006 45,74...45,81

103,960...104,006 45,74...45,81

Ø Deviation 0.25 width deviation 0.50

mm

103,810...103,856 46,24...46,31

103,810...103,856 46,24...46,31

Ø Deviation 0.50 width deviation 0.50

mm

103,560...103,606 46,24...46,31

103,560...103,606 46,24...46,31

Ø Deviation 0.75 width deviation 1.00

mm

103,310...103,356 46,74...46,81

103,310...103,356 46,74...46,81

Ø Deviation 1.00 width deviation 1.00

mm

103,060...103,106 46,74...46,81

103,060...103,106 46,74...46,81

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1007-02M

Main bearing axial play

mm

0,230...0,370

0,230...0,370

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1008-02M

Main bearing radial play

mm

0,060...0,126

0,060...0,126

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1009-02M

Hardness of main bearing and connecting rod journals (Rockwell hardness)

HRC

53...59

53...59

Check values of crankshaft

Number

Designation

ENGINE 457.9 EURO III standard

ENGINE 457.9 with CODE MS4, EURO IV standard, ENGINE 457.9 with CODE MS5, EURO V standard

BE03.20-N-1011-02M

Variation in concentricity measured at middle main fitted bearing journal (mounted at outer main bearing journals)

mm

 0,09

 0,09

 Crankcase, timing case cover, end cover

Number

Designation

Engine 457.9

BA01.40-N-1004-01U

Bolt, crankshaft bearing cap to crankcase

Stage 1

Nm

300

Stage 2

°

90

 Connecting rod

Number

Designation

ENGINE 457.9

BA03.10-N-1001-01L

Bolt, connecting rod bearing cap to connecting rod

Stage 1

Nm

110

Stage 2

°

90