Crank Mechanism, Dismantling
Crankshaft assembly, disassembling
Special tools:
999 5458 KEY 999 5458 Key
999 5679 Oil filter spanner 999 5679 Oil Filter Spanner
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Preparation
Remove:
- the oil trap
- the knock sensors (KS)
- the front engine mounting
- the oil pressure switch
- Evaporative emission system (EVAP) valve with hoses.
Remove:
- the bearing retainer for the right drive shaft
- the oil cooler and the rubber seals including hoses and pipes.
Removing the oil filter and oil pan
Remove:
- the oil filter. Use tool 999 5679 Oil filter spanner 999 5679 Oil Filter Spanner
- the screws holding the oil pump to the intermediate section.
Carefully tap the side of the oil pan with a rubber mallet.
Lift out the oil pan.
Removing the suction pipe from the oil pump
Remove:
- the O rings for the oil ducts
- the retaining screws holding the suction pump to the intermediate section. Work / lift out the suction pipe
- the O-ring for the suction pipe.
Check the pipe and the strainer. Check for cracks and impurities.
Checking markings
Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.
Turn the crankshaft so the piston in cylinder 1 is at bottom dead center (BDC).
Check that there are markings on the cap and connecting rods. Check which way the markings are positioned (exhaust and intake side). Make a note of this.
If necessary mark with a center punch or a number punch. See Crank mechanism, assembling, B5244T5, B5254T2 Crank Mechanism, Assembling.
New connecting rod
A new connecting rod has been introduced on certain engines.
The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated fracture surface.
Caution! If the cap is turned the wrong way and tightened, the structure of the fracture surface will be damaged and the connecting rod must then be discarded.
Note! Blow the fracture surface clean using compressed air before installing the cap.
Removing the pistons from the cylinder block
Caution! The bearing covers are not interchangeable. Also note the position of the bearing caps in relation to the rotation of the crankshaft.
Remove the screws for the connecting rod cover.
Lift off the cover. Ensure that the bearing cover comes with it.
Install tool in the connecting rod. Press out the connecting rod and piston.
Hold by hand so that the piston does not fall to the floor. Ensure that the bearing cover comes with it.
Place the piston and connecting rod in such a way that they will be reinstalled in the correct cylinder.
Continue with cylinders 2, 3, 4 and 5 as above.
Check
Check that the coolant guide is in place. Secure if necessary.
Removing the screwed joint from the intermediate section
First remove the M7 screws from the intermediate section.
Then remove the M8 screws. Start at the outer edges and work alternately towards the center.
Remove the M10 screws in the same way.
Separating the intermediate section from the cylinder block
Caution! The bearing covers are not interchangeable.Also note the position of the upper half of the axial bearing for the direction of rotation of the crankshaft.The crankshaft must not rotate.
Carefully pry the intermediate section from the cylinder block so that there is a gap of approximately 6-8 mm.
Then carefully tap off (on the exhaust side) the intermediate section with a rubber mallet.
Lift out the intermediate section. Ensure that the bearing covers for the intermediate section come with it.
Note! The bearing covers for the different bearing recesses are not interchangeable.
Ensure that the screws for the flywheel and carrier plate, which were installed earlier, are properly tightened. Lift them and the front of the crankshaft.
Carefully lift the crankshaft straight up.
Remove the remaining bearing covers.
Removing the piston cooling valve and nozzles
Remove the piston cooling valve at the front of the engine.
Remove the piston cooling nozzles.
Cleaning
Warning! A fume hood or extractor must be used when using gasket solution.
Clean the gasket surfaces on the cylinder block, intermediate section and oil pan.
Use a razor blade or a gasket scraper and / or gasket solvent (P/N 116 1440).