Checking, replacing and tightening conrod bolts - RA03001193100X(03-3100)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Operation no. of operation texts and work units or standard texts and flat rates 03-4341 bzw.

03-4351

STRETCH SHANK BOLT (1ST VERSION)¹⁾

Part no.

116 038 05 71

Thread Ø

M 10 X 1

Stretch shank Ø [(c) when new]

8.4-0.1

Min. stretch shank Ø (c)

8.0

4.2

Size

4.5

4.2

Length (L) (when new)

49.2-49.5

Conrod nut height (H)

⁽¹⁾	Engine 119.96

Fig 1: Identifying Shank Bolt Length (1st Version)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TIGHTENING TORQUES IN NM AND TIGHTENING ANGLE (NUT)

Engine 119.960

Conrod nut ⁽¹⁾

Initial torque

First tightening

Tightening angle

Repeat tightening

90°

⁽¹⁾	Nut and thread and contact surface of bolt moistened with engine oil before installing.

STRAIGHT STRETCH SHANK BOLT (2ND VERSION) 3)

Part no.

102 038 02 71

Thread Ø

M 9x1

Shank Ø [ (c)when new]

8.7-0.2

Min. shank Ø (c)

8.2

Length (L)

when new

52-0.3

max.

52.9

⁽¹⁾	Engine 119.97

Fig 2: Identifying Stretch Shank Bolt Length (2nd Version)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TIGHTENING TORQUE IN NM AND TIGHTENING ANGLE (STRAIGHT STRETCH SHANK BOLT)

Engine 119.97

Conrod bolt ⁽¹⁾

Initial torque

First tightening

Tightening angle

Repeat tightening

90°

⁽¹⁾	Thread and contact surface of bolt moistened with engine oil before installing.

STRAIGHT STRETCH SHANK BOLT (3RD VERSION) ⁽¹⁾

Part no.

111 038 00 71

Thread Ø

M 9 x 1

Length (L)

when new

52-0.3

max.

52.9

⁽¹⁾	Engine 119.97/98

Fig 3: Identifying Stretch Shank Bolt Length (3rd Version)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TIGHTENING TORQUE IN NM AND TIGHTENING ANGLE (STRAIGHT STRETCH SHANK BOLT)

Engine 119.97/98

Conrod bolt ⁽¹⁾

Initial torque

First tightening

Tightening angle

Repeat tightening

90°

⁽¹⁾	Thread and contact surface of bolt moistened with engine oil before installing.

Conrod bolts	re-use up to minimum stretch shank Ø or up to max. stretch shank length.
Thread and bolt head contact surface	oil before installing.
Conrod bolts	tighten initially with torque wrench 001 589 66 21 00.
Conrod bolts	tighten with tightening angle wrench; pay attention to tightening angle. The conrod bolts have different weights. Only conrod bolts of the same weight may be installed in an engine. NOTE: If no tightening angle wrench is available, the conrod bolt or conrod nut can be tightened further in a single step by the specified angle using a socket wrench and tommy bar. Do not use a flexi-bar torque wrench for tightening to degree settings in order to avoid any angle errors.

Special tool

Fig 4: Identifying Special Tools (001 589 66 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Replacing (1st version)

2 Knock out conrod bolts.

3 Press new conrod bolts into the conrod with a pressure of about 45,000 N or knock in with a hammer and drift. Place conrod on a ground steel plate (shop-made tool) when performing this step.

Fig 5: Identifying Ground Steel Plate Dimensions (Shop-Made Tool)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Tightening

4 Coat conrod nuts and thread and contact surface of conrod bolts with engine oil.

5 Tighten conrod nuts and conrod bolts, respectively.

Initial tightening torque

Engine 119.96 45 Nm

(55 Nm for new conrod bolt)

Tightening angle 90-100°

Engine 119.96: if conrod bolts knocked in with hammer, tighten the first time to initial torque of 55 Nm and then to a tightening angle of 90-100°.

It is essential to observe this instruction otherwise the nuts or conrod bolts may slacken.

Fig 6: Tightening Conrod Bolts

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.