11 21 500

Special tools required:

00 9 120
00 9 130
11 4 370
11 5 311
11 5 312
11 5 313
11 5 331
11 5 332
11 5 333
11 7 231
11 9 360

Important!

Remove all fit bolts first before releasing the crankcase lower section.
Altered settling behaviour at the crankcase!

If the main bearing channel is opened after engine operation, all main bearing shells must be replaced with special repair bearing shells marked with an (R).

There are two different groups of main bearing shells.

Necessary preliminary tasks:

Remove engine .

Mount engine on assembly stand .

Remove flywheel .

Removing oil sump .

Remove engine oil pump .

Remove VANOS high-pressure pump .

Remove cylinder head on left and right.

Remove all pistons .

Remove vibration damper .

Remove both timing chains .

Important!

Remove all fit bolts (2) first before releasing the crankshaft lower section – risk of damage!

Release all bearing seat bolts (1) from outside inwards.Installation:

Replace fine-mesh strainer (3).

Release screws (3).

Unfasten screws (2).

Release screws (1).

Lift out crankcase lower section (bedplate).

Lever out crankshaft (1) with aid of a second person in direction of arrow.Note:

Weight of crankshaft approx. 22 kg.

Important!

If the lower crankcase section (bedplate) is opened and closed again, fit special main bearing shells marked with (R) on the bearing backs.

Replace all bearing shells (1 and 2).Installation:

Replace main bearing shells .

Remove sealing compound from joint (1).

Carefully clean threads and contact surfaces in upper and lower sections of crankcase.

Installation:

Replace injector nozzles (2).

Replace O-rings for riser.

Installation:

Apply a light coating of engine oil to bearing shells.

Lay crankshaft (1) with a second person helping in direction of arrow into crankcase.Note:

Weight of crankshaft approx. 22 kg.

Important!

Adhere without fail to prescribed sequence for bolting crankcase lower section (bedplate).

Risk of damage to crankshaft.

Leaks on crankcase.

Important!

Do not use new bolts.

If new bolts are used, observe special tightening/torque specifications.

Note:

There are no more fitting sleeves in the crankcase.

Fit lower crankcase section (bedplate) on crankcase.

Position lower section diagonally on bearing seats (1 and 6) using two fit bolts (1).

Join fit bolts (1) to 8 Nm.

Insert remaining 10 fit bolts (1) and join to 8 Nm .

Insert all M11 bolts (1).

Tightening sequenceof

M11 and fit bolts .

Bearing seats (1 to 6).

Tightening sequence (1 to 12).

Tighten bolts M11 with special tools 00 9 120 and 00 9 130 .

Tightening torque: 11 11 1AZ .

Observe screwing sequence.

Tighten all fit bolts with special tools 00 9 120 and 00 9 130 .

Tightening torque: 11 11 2AZ.

Insert bolts (1).

Tightening torque: 11 11 3AZ.

Insert bolts (2).

Tightening torque: 11 11 4AZ.

Insert bolts (3).

Tightening torque: 11 11 5AZ.

Insert both timing chains.

Secure special tool 11 5 331 with bolts (1).

Important!

Pay attention to dowel pin.

Push special tool 11 7 231 onto special tool 11 5 331 in direction of arrow.

Installation:

Remove support ring from radial shaft seal.

Important!

Sealing lip of radial shaft seal is highly sensitive.

Sealing lip must not be kinked.

Do not touch the sealing lip with your fingers.

Push radial shaft seal (1) uniformly by way of fitting aid 11 7 231 onto special tool 11 5 331 .

Position radial shaft seal approx. 5 mm before crankcase.

Remove special tool 11 7 231 .

Press in radial shaft seal (1) with special tools 11 5 332 and 11 5 333 .

Important!

Pay attention to fitting sleeve.

Special tool 11 5 311 must rest flat on crankshaft (pay attention to fitting sleeve).

Install special tool 11 5 311 with bolts (1).

Position support ring (1) with radial shaft seal (2) on special tool 11 5 311 .

Push radial shaft seal (2) uniformly in direction of arrow over support ring onto special tool 11 5 311 .

Position radial shaft seal (1) approx. 5 mm before crankcase.

Remove support ring (2).

Note:

Support ring (2) is no longer needed.

Press in radial shaft seal (1) with special tools 11 5 312 and 11 5 313 .

Drive both injector nozzles with special tool 11 9 360 on left and right into crankcase.

Installation:

Always replace injector nozzles.

Installation:

Use primer 1.5 and liquid sealing compound 1.6 .

Prepare liquid sealing compound (2) in special tool 11 4 370 .

Screw on nozzle (1) for injecting liquid sealing

compound.

Press sealing compound cartridge (1) in direction of arrow onto nozzle at 90°.

Slowly and evenly insert sealing compound (1) with special tool 11 4 370 in direction of arrow.

Stop (seal off) escaping liquid sealing compound with primer (2) 1.5 at outlet bore (1).
The procedure is identical as on the rear radial shaft seal.
Assemble engine.