Removing and Installing Crankshaft
WM 134819 Removing and installing crankshaft
Preliminary work
Preliminary work
1. Remove engine.
2. Remove cylinder head.
3. Remove oil pan.
4. Remove oil pump.
Removing crankshaft
Removing crankshaft
Overview, crankshaft and bearings
1 - Crankshaft
2 - Straight pin
3 - Feather key
4 - Thrust washer, insert with grease no. 000.043.204.17
5 - Upper crankshaft bearing shell, lubricate with motor oil
6 - Lower crankshaft bearing shell, lubricate with motor oil
7 - Radial shaft sealing ring, crankshaft
H - Main bearing, location of color dots
P - Connecting rod bearing, location of color dots
Information:
The color codes of the crankshaft bearings and bearing shells must match!
To ensure that the bearings and bearing shells are of a matching class during installation, the bearing numbers are to be written on the backs of the bearings during removal of the main bearing shells with a waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as the main bearing shells.
New bearing shells are always to be installed when the engine is repaired.
1. Remove chain drive wheel from crankshaft. Unscrew fastening screw on belt pulley. Pull off chain sprocket with drive chain on oil pump; do not lose feather key when doing so.
Belt pulley fastening screw
Chain sprocket and feather key
2. Unscrew the four hexagon socket head bolts on the clutch side (M8).
Clutch side
3. Unscrew the outer cross bolt connection (M8 x 70) in the opposite order to the sequence shown.
External cross bolt connection
4. The figures below indicate the tightening sequence. The fastening screws are undone in the opposite order to the tightening sequence shown.
Outer bearing seat
5. Undo inner bearing seat in the opposite order to the tightening sequence shown.
Inner bearing seat
6. Remove lower part of crankcase.
7. Remove any remaining sealant and the old sealing ring in the upper part of the crankcase.
8. Fit holding bridges 9677 on the crankshaft -arrows-.
Holding bridges
9. Remove pistons. Rotate engine block in engine stand through 180° so that the crankshaft can be removed.
Caution:
Danger of crushing!
Risk of crushing your hands when lifting the crankshaft.
- Hold the very outside of the crankshaft.
- Wear gloves.
10. Undo holding bridges 9677 and carefully remove crankshaft upwards.
Installing crankshaft
Installing crankshaft
Information:
If no clear markings can be seen after thorough cleaning of the crankshaft and the bearings, the crankshaft and the corresponding bearing shells are to be replaced.
Information:
The bearing shells are available in various tolerance classes. The classes are indicated by the color marking on the outside -refer to Figure-. The color marking must match the corresponding color dot on the crankshaft. The colors are red, yellow and blue and must match between the bearings and the crankshaft.
Color marking on the outside
To ensure that the bearings and bearing shells are of a matching class during installation, the bearing numbers are to be written on the backs of the bearings during removal of the main bearing shells with a waterproof felt-tipped pen, due to that fact that the ink markings wear off of the crankshaft journals as well as the main bearing shells.
New connecting rod bearings main bearing shells are always to be installed when the motor is repaired.
1. Insert the bearing shells with the lubricating groove into the upper part of the crankcase. Make sure the twist locks are positioned correctly -see figure-. Then lightly oil the bearing locations.
Correct position of the twist locks
2. Insert the sickle-shaped washers (ensure axial bearing play). To do this, insert the two sickle-shaped washers (thrust washers) on the left and right on crankshaft bearing No. 3 with some grease (000.043.204.17) -see figure- to prevent the sickle-shaped washers from falling off. Each of the lubricating grooves of the sickle-shaped washers must be facing outwards.
Sickle-shaped washers (thrust washers)
Caution:
Heavy components
Risk of squashing
- Wear personal protective gear.
- Get someone to help if necessary.
3. Insert the crankshaft. The connecting flange must point towards the back of the engine. Then secure the crankshaft from falling down using holding bridges 9677. Fix the holding bridges at bearing locations 3 and 5. Screw the fastening screw from the belt pulley at the front into the crankshaft and tighten slightly so that the crankshaft can be turned -see figure-.
Turning the crankshaft
4. Turn crankcase by 180° on the assembly support.
5. Install pistons.
6. Turn crankcase again through 180° on the assembly support.
7. Make sure the crankcase is ready to be screwed in. Check that the sickle-shaped washers are positioned correctly. Degrease parting surfaces between the upper and lower part of the crankcase. A totally grease-free product (e.g. brake cleaner) must be used for this. Then insert a new O-ring at the front of the parting surface -3-.
Lower part of crankcase
1 - Lower part of crankcase
2 - Cylindrical pin used to center the lower part of the crankcase on the crankcase
3 - Sealing ring; replace
4 - Application of sealant; Drei Bond Silikon 2210 liquid sealant (000.043.204.58, status 02/06) must be applied and the screws screwed in within five minutes and without interruption
5 - Thrust-bearing screw, M12 x 1.5 x 132
6 - Thrust-bearing screw, M10 x 117
7 - Fastening screw, M8 x 70
8 - Fastening screw, M8 x 35
9 - Fastening screw, M8 x 50
10 - Dowel sleeve
8. Screw the two thin centering pins 9321 into the outer fastening bores on the upper part of the crankcase -see illustration (shown without crankshaft)-.
Centering pins
9. Insert bearing shells into lower part of crankcase and lightly oil them. When doing so, ensure that the twist locks (retaining lugs) fit into the appropriate recesses in the lower part of the crankcase.
Twist locks (retaining lugs)
Information:
The liquid sealant must be applied and the screws screwed in within five minutes at most and without interruption.
The required tool (torque wrench for 15 Nm (11 ftlb.) to 40 Nm (30 ftlb.); torque angle wrench; socket wrench E12, E14 and E14) must be ready for use.
The threads and head contact surface of the bearing seat screws (M10 x 1.5 and M12 x 1.5) must be oiled.
10. Apply Drei Bond Silikon 2210 liquid sealant (000.043.204.58, status 02/06) to the lower part of the crankcase as shown. The outer surfaces marked -A- must be cleaned after fitting.
Applying sealant
11. Place lower part of crankcase into position. When doing so, make sure that the sealing bead is not destroyed.
Information:
Unscrew the centering pins again while securing the lower part of the crankcase.
12. The figures below indicate the tightening sequence. The screws are tightened in four steps. It is essential that the tightening sequence is observed here. The screws must be tightened within five minutes.
- Initial tightening: 40 Nm (30 ftlb.)
- Initial tightening: 22 Nm (16 ftlb.)
- Final tightening: 75°
- Final tightening: 60°
Inner bearing seat
Tightening sequence, inner bearing seat
Outer bearing seat
Tightening sequence, outer bearing seat
13. Then screw on the outer cross bolt connection (M8 x 70) in the sequence shown - Tightening torque: 23 Nm (17 ftlb.).
Tightening sequence, outer cross bolt connection
14. Tighten the four hexagon socket bolts on the clutch side (M8 x 35) - Tightening torque: 23 Nm (17 ftlb.).
Clutch side
15. Fit chain drive sprocket on the crankshaft. Unscrew fastening screw on belt pulley. Check that the feather keys are fitted correctly and push on the chain sprocket with the oil pump drive chain. The double-tooth row must be facing forwards.
Chain drive sprocket
Subsequent work
Subsequent work
1. Install oil pump.
2. Install oil pan.
3. Install cylinder head.
4. Install chain case lid.
5. Install engine.