Remove and install crankshaft (Z 12 XE, Z 12 XEP,
Z 14 XEP, without air conditioning)
Remove
1. |
Remove and install engine - See operation J 340100 "Removing
and installing engine" in group "J"
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2. |
Removing and installing manual transmission from engine - see
operation "J 340100-007 Manual transmission to engine, remove and
install"
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3. |
Install engine
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Attach KM-412-18 (1) to engine
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Install engine in KM-412 (2)
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Tighten 8 bolted connections
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4. |
Drain engine oil
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Place collecting basin underneath.
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Remove oil filter housing cover
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Remove oil filter element
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5. |
Detach clutch (1) - see operation "Remove and install thrust
plate and clutch disk" in group "K"
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7. |
Detach right engine bracket
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8. |
Install oil drain screw
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9. |
Remove ribbed V-belt
Note: Mark running
direction.
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Tension ribbed V-belt tensioner in direction of arrow
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Remove from crankshaft ribbed V-belt pulley
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10. |
Detach coolant pump ribbed V-belt pulley
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11. |
Detach crankshaft ribbed V-belt pulley
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Counterhold at crankshaft hub bolt
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12. |
Detach ribbed V-belt tensioner
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Unscrew 2 bolts (arrows)
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13. |
Remove alternator wiring harness (1)
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15. |
Remove wiring harness for engine management
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Disconnect wiring harness connector.
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Oil pressure switch (2), coolant temperature sensor (3),
camshaft sensor (4) ignition module (1), crankshaft sensor (5)
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16. |
Detach 3 coolant hoses from coolant pump
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17. |
Detach coolant pump (1)
Note: Note guide
bushings during removal
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Place collecting basin underneath.
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Unscrew 9 bolts
Note: Pay attention to
different bolt lengths (arrows = short bolts)
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18. |
Remove ignition module
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Remove ignition module cover
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Extract using KM-6009 (1)
Note: Do not tilt
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19. |
Unscrew 4x spark plugs with KM-194-E
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20. |
Detach cylinder head cover
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Detach engine vent hose
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21. |
Loosen crankshaft hub bolt (1)
Note: Second person
required
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Attach KM-956-1 KM-956-2 (2)
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Counterhold KM-956-1 KM-956-2
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22. |
Adjust camshafts
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Uniformly rotate crankshaft in direction of engine rotation
with KM-956-1 KM-956-2 until KM-953 (1)
engages in camshaft groove as far as it will go
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23. |
Remove crankshaft hub
Note: Pay attention to
installation position
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Remove with KM-956-1 KM-956-2
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25. |
Detach camshaft sensor (1)
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26. |
Remove timing case
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Unscrew 15 bolts (arrows)
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Pay attention to bolt lengths
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Lever out timing case seal ring
Note: Do not damage
sealing surface
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27. |
Remove chain drive
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Loosen camshaft sprocket bolts
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Counterhold camshafts at hexagonal section
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Detach sliding rail (3), guide rail (5), tension rail (7) and
camshaft sprockets
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Remove timing chain (4) with drive sprocket (6)
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Remove timing case gasket.
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28. |
If present: detach oil baffle plate (1)
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29. |
Remove crankshaft sensor
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30. |
Remove con-rod bearing cap
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Mark 4 con-rod bearing caps (2)
Note: Observe cylinder
sequence
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Important: The mating surfaces of
the cod-rods and con-rod bearing caps form an individual fit and
must not be damaged or interchanged. Do not lay on mating
surfaces.
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Remove 4 con-rod bearing caps
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31. |
Remove crankshaft
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Remove crankshaft bearing bridge
Note: Prise off
evenly
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Remove crankshaft rear seal ring
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Place crankshaft on wooden blocks
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32. |
Remove crankshaft bearing shells
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33. |
Remove crankshaft bearing shells
Note: Observe order
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Mark crankshaft bearing shells
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34. |
Remove con-rod bearing shells
Note: Observe order
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Mark con-rod bearing shells
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35. |
Remove crankshaft pulse pickup disc (1)
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36. |
Remove oil intake pipe (1)
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Install
37. |
Clean sealing surfaces
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Cylinder block, cylinder head, cylinder head cover, crankshaft
bearing bridge, chain drive, timing case, oil pan, coolant pump,
exhaust manifold
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38. |
Inspect components
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Cylinder block, cylinder head, cylinder head cover, crankshaft
bearing bridge, chain drive, timing case, oil pan, coolant pump
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39. |
Check whether crankshaft bearing bridge is level using a
straightedge and a feeler gauge
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40. |
Attach crankshaft pulse pick-up disk
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41. |
Insert con-rod bearing shells
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In con-rod, con-rod bearing cap
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42. |
Insert crankshaft bearing shells
Note: Pay attention to
position of axial bearing (arrow)
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Insert crankshaft bearing bridge into cylinder block
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43. |
Insert crankshaft
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Coat crankshaft journal with engine oil
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44. |
Install crankshaft bearing bridge
Note: Complete
installation work within 10 minutes
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Apply sealant to outer edge of groove (dimension I = 2 mm)
Note: Do not apply
sealant in groove
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Tighten 10 bolts (M8) 25 Nm +
60°
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Tighten 12 bolts (M6) 10 Nm +
60°
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45. |
Install rear crankshaft seal ring (1)
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Coat sealing lip with silicone grease
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Position KM-235-6 (2) on crankshaft
journal
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Slide seal ring onto KM-235-6
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Drive in until flush using KM-658-1
(3)
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46. |
Attach con-rod bearing cap
Note: Bead on con-rod
bearing cap faces transmission side
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Tighten 8 bolts (M6) 10 Nm + 60° +
15°
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From engine number 19P13554 ( 13 Nm +
60° + 15° ) (M6.5)
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47. |
Lock crankshaft
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Remove closure bolt (1)
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Insert KM-952 (2)
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Turn crankshaft uniformly until KM-952 engages
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48. |
Replace timing case gasket
Note: Complete assembly
operations within 10 minutes
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Apply sealant
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Cut off excess elastomer of cylinder head gasket (1) and
replace with a 2 mm thick bead of silicone sealant
Note: If no excess
elastomer is present, the bead of silicone sealant can be applied
directly
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Apply silicone sealant to joint between cylinder block and
crankshaft bearing bridge
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49. |
Attach timing chain
Note: Ensure that guide
sleeves are correctly seated (arrows)
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Position exhaust camshaft
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Install timing chain (3)
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Insert intake camshaft sprocket with phase sensor disc in
timing chain
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Bolt in bolt
Note: It must be
possible to rotate phase sensor disk by hand
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50. |
Attach timing chain tension rail (6)
Note: Ensure that
timing chain is correctly seated
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51. |
Attach timing chain guide rail (4)
Note: Ensure that
timing chain is correctly seated
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52. |
Attach timing chain sliding rail (2)
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53. |
Release chain tensioner
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54. |
Attach coolant pump
Note: Ensure that guide
sleeves are correctly seated (arrows)
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Attach using short bolts (2)
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Remove thermostat housing cover
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55. |
Attach timing case.
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Tighten 5 bolts (1) (M6) 8 Nm
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Tighten 14 bolts (2) (M6) 8 Nm
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Tighten 2 bolts (3) (M10) 35 Nm
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Attach thermostat housing cover
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56. |
Replace crankshaft front seal ring (1)
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Coat sealing lips with silicon grease
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Drive in until flush using KM-960
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57. |
Remove KM-952
Note: Retaining tools
must not be used for counterholding
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58. |
Attach crankshaft hub
Note: Note crankshaft
hub (2) installation position - mark must point upwards
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Counterhold with holder KM-956-1
KM-956-2 (3)
Note: Second person
required
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Tighten bolt 150 Nm + 45°
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Detach KM-956-1 KM-956-2
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59. |
Attach crankshaft ribbed V-belt pulley (1)
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Counterhold at crankshaft hub bolt
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61. |
Attach KM-954 (1)
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Rotate phase sensor disk (2) until KM-954 can be attached to timing case
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62. |
Fasten camshaft sprockets
Note: Tightening torque
of 10 Nm is used to secure the camshaft sprockets and the phase
sensor disk
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Tighten 2 bolts (2) 10 Nm
Note: First tighten
intake camshaft sprocket bolt
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Counterhold camshafts at hexagonal section (1)
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63. |
Remove retaining tools
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KM-952 , KM-953 , KM-954
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64. |
Fasten camshaft sprockets
Note: Second person
required
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Tighten 2 bolts 50 Nm + 60°
Note: First tighten
intake camshaft sprocket bolt
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Counterhold camshafts at hexagonal section
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66. |
Remove retaining tools
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KM-952 , KM-953 , KM-954
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67. |
If present: attach oil baffle plate
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68. |
Attach oil pan
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Align oil pan to cylinder block using straight edge
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69. |
Attach closure bolt of crankshaft bearing bridge
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70. |
Install crankshaft sensor
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71. |
Attach cylinder head cover (1)
Note: Complete assembly
operations within 10 minutes
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Renew gasket (2) and seal rings
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Apply sealant (dimension I = 2 mm)
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Attach engine vent hose
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72. |
Install 4 spark plugs
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Tighten using KM-194-E 25 Nm
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73. |
Attach ignition module
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Attach ignition module cover
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74. |
Attach camshaft sensor
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75. |
Attach 3 coolant hoses
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76. |
Install engine management wiring harness
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Connect 5 wiring harness plugs
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78. |
Install alternator wiring harness
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79. |
Attach ribbed V-belt tensioner
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Tighten bolt (M8) 20 Nm
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Tighten bolt (M10) 55 Nm
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80. |
Attach coolant pump ribbed V-belt pulley
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81. |
Install ribbed V-belt
Note: Observe running
direction and installation position
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Release ribbed V-belt tensioner
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82. |
Attach right engine bracket
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83. |
Attach flywheel
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Clean threads in crankshaft
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Tighten 6 bolts 35 Nm + 30°
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Apply screw locking compound
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84. |
Attach clutch - see operation "Remove and install thrust plate
and clutch disk" in group "K"
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85. |
Top up engine oil
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Check engine oil level, if necessary correct.
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86. |
Detach engine
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Suspend engine on workshop crane
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Detach from KM-412
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Undo 8 screw connections
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