Crank Mechanism, Assembling
Crank mechanism, assembling
Special tools:
999 5746 Holder 999 5746 Holder
999 5679 Oil filter spanner 999 5679 Oil Filter Spanner
Note! 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.
Preparatory work
Cleaning
Make sure that all included parts are well cleaned.
Blow clean the oil ducts in the block, intermediate section and sump.
Classification of bearings
1. Marking crankshaft bearing
2. Marking connecting rod bearing.
2. Marking connecting rod bearing
1. Marking crankshaft bearing
2. Marking connecting rod bearing.
Classification of main bearings
Note! Note the classification marking on each bearing (se illustration).
Wipe clean the bearing recesses in the block and the intermediate section.
Check that the components are clean and undamaged.
Selecting bearings
Note! Always use new bearings, install the correct classification in the correct bearing recess.
Lubricate and install the main bearings in the cylinder block and intermediate section. The axial bearing is positioned at bearing recess 3.
Installation
Note! Tightening torque: Refer to: Tightening torque, B8444S [1][2]Specifications
Installing crankshaft
Install the two old screws for the flywheel and carrier plate at the rear edge of the crankshaft.
Lift these and the front of the crankshaft.
Carefully lay the crankshaft into place in the block.
The crankshaft may not be rotated before the intermediate section is torque-tightened.
Applying liquid gasket
Note! Minimum 1 mm bead thickness.
Note! Install the intermediate section within 5 minutes. (curing time of liquid gasket).
Wipe the surfaces dry.
Apply liquid gasket 307 57050 to the intermediate section as illustrated. Thoroughly lubricate the surface of the axial bearing and all bearing shells.
Installing intermediate section
Note! Use new M10-screws.
Lubricate and install all the screws. Position the intermediate section.
Tighten the intermediate section to the cylinder block. Step 1. Refer to: Tightening torque, B8444S [1][2]Specifications
Tighten the intermediate section to the cylinder block. Step 2. Refer to: Tightening torque, B8444S [1][2]Specifications
Classification of pistons
Select piston according to (see illustration):
1. classification
2. marking forward in the cylinder block.
Assembling pistons and connecting rods
Warning! The snap ring can easily come off. Wear protective goggles.
The marking on top of the piston must be turned forwards in the cylinder block.
The connecting rods are symmetrical and can be turned arbitrarily. However, marked connecting rods must be turned to face the same way.
Assemble the connecting rod and piston with the piston pin. Check that the classification and any numbering for each cylinder/piston diameter and connecting rod correspond.
Install both the snap rings on the piston pin. Check that the snap rings are positioned correctly in the piston. The opening must be vertical (see illustration). Wipe clean around the bearing recess in the connecting rod and the cap.
Installing the main bearing shells, connecting rods
Installing piston rings
Caution! Ensure that the piston rings can be turned easily.
Note! Incorrect positioning may result in higher oil consumption.
Use piston ring pliers. Turn the piston rings so that the openings are offset as illustrated.
1. Compression ring
2. Lower oil scraper ring
3. Lower oil scraper ring
4. Expander ring
5. Upper oil scraper ring.
Installing the pistons in the cylinder bores
Note! The marking on top of the piston must point forwards. Ensure that the classifications correspond.
Use a cylinder ring compressor.
Lubricate the cylinder bore, the pistons and the bearing shells.
Turn the crankshaft so that the crank pin is in bottom dead center (BDC) for the cylinder that the piston is to be installed in.
Ensure that the engine is in a position where the cylinder bore forms as vertical a line as possible.
Carefully press/tap down the piston (e.g., with the handle of a hammer).
When the piston releases from the piston ring compressor, remove the piston ring compressor and turn the engine 180° in the stand.
Install tool 999 5746 Holder 999 5746 Holder in the connecting rod. Pull the connecting rod until it secures against the big end journals.
Tightening the connecting rod cover
Note! The crankshaft must not be rotated before the connecting rod cover has been tightened.
Install the cap. Check that any markings correspond. Lubricate and install new screws. Tighten the connecting rod cover. Refer to: Tightening torque, B8444S [1][2]Specifications
Check that the connecting rod can be moved sideways.
Installing the oil pump
Install:
- the oil pump
- the screws, 3 pcs M6, for the oil pump. Tighten. Refer to: Tightening torque, B8444S [1][2]Specifications
Install:
- the oil splash plate.
- the nuts, 5 x M8, and the screw 1 x M6. Tighten
- a newgasket for the oil delivery pipe
- the oil delivery pipe
- the nuts, 2 x M6, and 2 x M8. Tighten
Installing oil pan
Applying liquid gasket
Note! Clean all mating surfaces using a razor blade or plastic scraper.
Apply liquid gasket 307 57050 as illustrated.
Note! Minimum 1 mm bead thickness.
Note! Install the oil pan within 5 minutes. (curing time of liquid gasket).
Install:
- the oil pan. Use new O-rings
- the screws holding the oil pan to the intermediate section, 17 x M8 and 1 x M6. Tighten. Refer to: Tightening torque, B8444S [1][2]Specifications
Note! Clean all mating surfaces using a razor blade or plastic scraper.
Apply liquid gasket 307 57050 as illustrated.
Note! Minimum 1 mm bead thickness.
Note! Install the oil pan within 5 minutes. (curing time of liquid gasket).
Install:
- the 20 x M6 screws. Tighten. Refer to: Tightening torque, B8444S [1][2]Specifications
- oil level sensor. Tighten
- oil filter insert, use a new O-ring
Install:
- a new O-ring for the oil cooler
- the 4 x M6 screws. Tighten
Install a new oil filter and a newO-ring. Use: 999 5679 Oil filter spanner 999 5679 Oil Filter Spanner.