AR03.20-P-4351AV Remove/Install Crankshaft

Remove/install crankshaft








Remove

DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

1 Remove engine.
2.1 Detach automatic transmission from engine.
2.2 Detach manual transmission from engine.
3 Detach top part of oil pan.
4 Remove oil pump.

NOTE: Push back chain tensioner for this step and take off chain.

5 Detach belt pulley/vibration damper.
6 Detach flywheel/driven plate.
7 Take off end cover.
8 Take off timing case cover.
9 Remove conrod bearing cap (16).

NOTE:
- When rotating the crankshaft ensure, that the connecting rod (11) does not tilt.
- Mark conrod (11) and conrod bearing cap (16) on one side to each other for this step.

10 Unbolt crankshaft bearing caps.

NOTE: Pay attention to slackening diagram.

11 Remove crankshaft bearing caps (4, 10) and fitted bearing (5).

NOTE: Before removing mark the crankshaft bearing caps (4,10) and fitted bearing (5). Carefully lever out crankshaft bearing caps (10) and (5).

12 Take crankshaft (1) out of the crankcase.
13 Take crankshaft bearing shells (2) and thrust washers (6) out of the crankcase.

Install
14 Insert crankshaft (1).

NOTE: Oil crankshaft journals and crankshaft bearing shells (2)!
- If crankshaft is replaced.
- If crankshaft is repaired.

15 Tighten crankshaft bearing caps.

CAUTION: The crankshaft bearing cap bolts M8X75 and M10X90 must always be replaced otherwise there is a risk of fracture. At the same time tighten all bolts (M10, M8) synchronously as specified in the tightening pattern!

- Tightening pattern.

16 Check axial play of crankshaft.
- If crankshaft is replaced.

17 Check connecting rod bolts (12)
- Inspection data: Thread and shank length

18 Install conrod bearings and fit on conrod bearing caps (16).

CAUTION:
- The connecting rod bearing shell (13) with the oil hole (arrow) must be mounted in the connecting rod (11) otherwise the connecting rod bearings are not greased. The anti-twist locks (14) of the connecting rod bearing shells (13) must be seated in the grooves (15) of the connecting rod (11) and the connecting rod bearing cap (16).
- Connecting rod (11) and connecting rod bearing cap (16) are cracked (broken) (magnified section). They must not be installed laterally inverted as the dimensional accuracy would no longer be there.

19 Tighten connecting rod bolts (12).
20 Rotate crankshaft.

NOTE: To inspect ease of operation.

21 Fit on end cover.

NOTE: Replace radial seal!

- The sealing lip of the radial seal and its mating surface must not be oiled or greased.
- Pay attention to dowel sleeves when pressing on end cover.

22 Fit on flywheel/driven plate.
23 Fit on timing case cover.

NOTE: Replace O-rings and radial seal.

- The sealing lip of the radial seal and its mating surface must not be oiled or greased
- Pay attention to dowel sleeves when pressing on end cover!

24 Fit on belt pulley/vibration damper
25 Attach oil pump.

CAUTION:
- Ensure oil return flow check valve is correctly located.
- Clean strainer of oil pump.
- Fill oil pump with engine oil before installing so that oil is transported when it is first started.

26 Fit on top part of oil pan.
27 Check timing of engine.
28.1 Fit on automatic transmission.
28.2 Fit on manual transmission.
29 Install engine.