Measuring crankshaft and remounting in bearings - AR03.20-P-4355AW

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ENGINE 601, 602, 603 (except 602.98)

Shown on engine 601

The thrust washers (22) in the bearing cap each have two retaining lugs as an anti-twist lock. The oil grooves (arrow) in the thrust washers (22) and (23) must point toward the thrust shoulders of the crankshaft.

Fig 1: Identifying Crankshaft And Bearing

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove
1	Remove crankshaft		*BA03.20-P-1001-01A
		Installation : Inspect length of bolt of crankshaft bearing cap, replace if necessary (2nd version)	*BA03.20-P-1002-01A
		Pay attention to fit	AH03.20-P-4351-02A
		Bearing diagram	AH03.20-P-4351-01AW
2	Clean engine parts	After bearing damage has occurred, it is necessary to remove any swarf from the conrod bores and from the crankshaft and crankcase oil galleries ↓ Clean main oil gallery, seal	ra01006010130x
	Inspect
3	Inspect conrod, repair if necessary	After a bearing damage has occurred: Replace conrods which have suffered overheating because of bearing damage (blue discoloration). The conrod shank must not have any cross scores and notches.	AR03.10-P-6111AW
4	Inspect crankshaft	After a bearing damage has occurred: Visual inspection! If damage is present ↓ Inspect crankshaft, repair	ra03006010318x
5	Mount crankshaft radially in bearings		AR03.20-P-4355-01AW
		Inspection data of main bearing play	*BE03.20-P-1001-04C
		Inspection data of conrod bearing play	*BE03.20-P-1002-04C
		Inspection data of crankcase	*BE01.40-P-1001-02D
		Inspection data of main bearing shells	*BE03.20-P-1001-03B
		Inspection data of crankshaft bearing journal Ø	*BE03.20-P-1001-02C
		Inspection data of main bearing journal Ø	*BE03.20-P-1002-02C
		Crankshaft bearing cap	*BA03.20-P-1001-01A
		Conrod bolt	*BA03.10-P-1001-01C
		Conrod bolt	*BA03.10-P-1002-01C
			Figure
			*WH58.30-Z-1012-12A
			*WH58.30-Z-1001-12A
		Radial mounting of the main bearings of standard size crankshafts is possible by assigning the color-coded bearing shells, refer to ↓ Assign crankshaft bearing shells	AR03.20-P-4360-01HA
6	Mount crankshaft axially		AR03.20-P-4355-02AW
		Inspection data of axial bearing play	*BE03.20-P-1001-04C
		Inspection data of fit bearing journal width	*BE03.20-P-1003-02C
		Crankshaft bearing cap	*BA03.20-P-1001-01A
			Figure
			Figure
			*WH58.30-Z-1012-12A
			*WH58.30-Z-1001-12A
7	Install in the reverse order

INSPECTION DATA OF CRANKSHAFT MAIN BEARING SHELLS

Number	Designation			Engine 601, 602 except 602.982, 603
BE03.20-P-1001-03B	Main bearing shells standard dimension for crankcase and bearing cap Ø 58.00 mm	Replacement part additional number (color coding blue)		52
BE03.20-P-1001-03B		Bearing shell thickness	mm	2,255-2,260
BE03.20-P-1002-03B	Main bearing shells standard dimension for crankcase and bearing cap Ø 58.00 mm	Replacement part additional number (color coding yellow)		54
BE03.20-P-1002-03B		Bearing shell thickness	mm	2,260-2,265
BE03.20-P-1003-03B	Main bearing shells standard dimension for crankcase and bearing cap Ø 58.00 mm	Replacement part additional number (color coding red)		56
BE03.20-P-1003-03B		Bearing shell thickness	mm	2,265-2,270
BE03.20-P-1004-03B	Main bearing shells standard dimension for bearing cap Ø 58.00 mm	Replacement part additional number (color coding white)		57
BE03.20-P-1004-03B		Bearing shell thickness	mm	2,270-2,275
BE03.20-P-1005-03B	Main bearing shells standard dimension for bearing cap Ø 58.00 mm	Replacement part additional number (color coding purple)		58
BE03.20-P-1005-03B		Bearing shell thickness	mm	2,275-2,280
BE03.20-P-1006-03B	Main bearing shells repair size 1 for crankcase and bearing cap Ø 57.70 mm	Bearing shell thickness	mm	2,37
BE03.20-P-1007-03B	Main bearing shells repair size 2 for crankcase and bearing cap Ø 57.40 mm	Bearing shell thickness	mm	2,50
BE03.20-P-1008-03B	Main bearing shells repair size 3 for crankcase and bearing cap Ø 57.20 mm	Bearing shell thickness	mm	2,62
BE03.20-P-1009-03B	Main bearing shells repair size 4 for bearing caps Ø 56.90 mm	Bearing shell thickness	mm	2,75

INSPECTION DATA OF CRANKCASE

Number	Designation			Engine 601, 602.91/96, 603.91/96
BE01.40-P-1001-02D	Crankshaft bearing	Basic bore diameter	mm	62,500-62,519
		Basic bore width at fit bearing	mm	19,979-20,000
		Permissible out-of-roundness and conicity of basic bore	mm	0,02

INSPECTION DATA OF CRANKCASE

Number	Designation			Engine 603.97
BE01.40-P-1001-02D	Crankshaft bearing	Basic bore diameter	mm	62,500-62,519
		Basic bore width at fit bearing	mm	19,979-20,000
		Permissible out-of-roundness and conicity of basic bore	mm	0,02

INSPECTION DATA OF CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 601, 602 except 602.982, 603
BE03.20-P-1001-04C	Main bearing play	Radial, when new	mm	0,03-0,05
		Radial, wear limit	mm	0,08
		Axial, when new	mm	0,10-0,25
		Axial, wear limit	mm	0,3
BE03.20-P-1002-04C	Conrod bearing play	Radial, when new	mm	0,020-0,065

TEST VALUES FOR CRANKSHAFT

Number	Designation			Engine 601 up to 06/84	Engine 601 as of 07/84, 602 except 602.98, 603
BE03.20-P-1001-02C	Crankshaft bearing journal Ø	Standard size	mm	57,940-57,965	57,940-57,965
		1st repair size	mm	57,700-57,715	57,700-57,715
		2nd repair size	mm	57,450-57,465	57,450-57,465
		3rd repair size	mm	57,200-57,215	57,200-57,215
		4th repair size	mm	56,950-56,965	56,950-56,965
BE03.20-P-1002-02C	Conrod journal Ø	Standard size	mm	47,940-47,965	47,940-47,965
		1st repair size	mm	47,700-47,715	47,700-47,715
		2nd repair size	mm	47,450-47,465	47,450-47,465
		3rd repair size	mm	47,200-47,215	47,200-47,215
		4th repair size	mm	46,950-46,964	46,950-46,964
BE03.20-P-1003-02C	Fit bearing journal width	Standard size	mm	26,500-26,520	24,500-24,533
		Repair size	mm	26,600-26,620	24,600-24,633
			mm	26,700-26,720	24,700-24,733
			mm	26,900-26,920	24,900-24,933
			mm	27,000-27,020	25,000-25,033

INSPECTION DATA OF CRANKSHAFT BEARING CAP BOLTS

Number	Designation			Engine 601, 602 except 602.982, 603
BE03.20-P-1001-01B	Bolt of crankshaft bearing cap (2nd version)	Thread diameter	M	11
		Length (L) when new	mm	62,0
		max. length (L)	mm	63,8
		Fig. see		AR03.20-P-4351-03A

CRANKSHAFT BEARING CAP

Number	Designation				Engine 601, 602, 603 except 602.98
BA03.20-P-1001-01A	Bolt crankshaft bearing cap	M11	1st stage	Nm	55
BA03.20-P-1001-01A	Bolt crankshaft bearing cap	M11	2nd stage	∠ °	90
BA03.20-P-1002-01A	Bolt of crankshaft bearing	M12		Nm	90

CONROD

Number	Designation				Engines 601, 602 except 602.98, 603 except 603.970 up to 11/90 603.970 up to 8/90	Engines 601, 602 except 602.98, 603 except 603.970 as of 12/90 - 10/92 603.970 as of 9/90 - 10/92	Engines 601, 602 except 602.98, 603 as of 11/92
BA03.10-P-1001-01C	Conrod screw (stretch shank)	1st stage	new	Nm	-	45	40
		1st stage	used	Nm	-	40	-
		2nd stage		∠ °	-	90	90
		Fig. see			-	AR03.10-P-6111-01AW	AR03.10-P-6111-01AW
BA03.10-P-1002-01C	Conrod bolt (stretch bolt)	1st stage		Nm	30	-	-
		2nd stage		∠ °	90	-	-
		Fig. see			AR03.10-P-6111-01AW

Fig 2: Identifying Dial Gage (001 589 32 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Dial Gage Holder (363 589 02 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1001-12A	Quick calipers for internal measurements
WH58.30-Z-1012-12A	Setting gage for micrometer