Mounting crankshaft in bearings - RA030A1193200X(03-3200)

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Preceding work:

Engine removed and disassembled.

Oil galleries in crankcase and in crankshaft cleaned.

Crankshaft examined for cracks, dimension of tolerance, hardness and concentricity.

Operation no. of operation texts and work units or standard texts and flat rates

03-4700, 6401, 7021

Engine 119.96/97 with fit bearing

Fig 1: Identifying Crankshaft, Vibration Damper And Belt Pulley

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

DATA IN MM

Crankshaft standard size and repair sizes

Crankshaft bearing journal Ø

Color Coding

Crankshaft journal width at fit bearing ⁽²⁾

Crankshaft bearing journal Ø

Crankshaft bearing journal width

Standard size

63,9601 ⁽¹⁾

→

blau

27,000

47,965

50,000

63,965

27,021

47,955

50,100

63,955 ⁽¹⁾

→

gelb

63,960

63,950 ⁽¹⁾

→

rot

63,955

1st repair size

63,715

max.27,50

47,715

63,700

47,705

2nd repair size

63,465

47,465

max.50,30

63,450

47,455

3rd repair size

63,215

47,215

63,200

47,205

4th repair size

62,965

46,965

62,950

46,955

⁽¹⁾	Tolerance division for bottom bearing cap, colored dots on crank webs or counterweights next to crankshaft bearing journals

⁽²⁾	Crankshaft main bearings with fit bearing as of engine no. 119.96 as of start of production up to engine no. 119.970 12 036277 119.971 12 017447 119.972 12 004797 119.974 12 008072 119.975 12 010516

CRANKSHAFT BEARING BORE, CONROD BEARING BORE AND BEARING PLAY IN MM

Crankcase ⁽²⁾

Color coding

Conrod

Crankshaft bearing bore

68.480 ⁽¹⁾

→

blue

68.486

yellow

68.486 ⁽¹⁾

→

red

68.492

68.492 ⁽¹⁾

→

68.500

Conrod bearing bore

51.600

51.619

Permissible out-of-roundness and conicity of bores

0.01

Radial bearing play

when new

0.021-0.045⁽³⁾

0.030-0.055⁽³⁾

wear limit

0.090

0.080

Axial bearing play

when new

0.10-0.22

0.22-0.38

wear limit

0.30

0.50

⁽¹⁾	Tolerance division for top bearing cap, chisel punch points in contact surface of crankcase at oil sump end.

⁽²⁾	Machined together with crankshaft bearing cap.

⁽³⁾	Aimed for average value of radial bearing play.

MATCHING CRANKSHAFT BEARING SHELLS TO CRANKCASE

Chisel punch points on crankcase	Matching top bearing shell with color coding
Chisel punch points on crankcase	1 punch point	2 punch points	3 punch points
Colored dots on crankshaft bearing cap	Blue	Yellow	Red
Color of top bearing shell	Blue	Yellow	Red
Color coding on crankshaft	Matching bottom bearing shell with color coding
Color coding on crankshaft	Blue	Yellow	Red
Color of bottom bearing shell	Blue	Yellow	Red

TIGHTENING TORQUES IN NM

Crankshaft bearing stud bolt

Stud bolt in crankcase⁽¹⁾

M10x1 nut

M10x40 side bolts (10.9)

⁽¹⁾	The stud bolts lose their locking effect after being unscrewed and must therefore only be used once.

Special tools

Fig 2: Identifying Special Tool (001 589 72 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Special Tool (001 589 66 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Special Tool (363 589 02 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Quick-callipers for internal measurements, dia. 40 - 60 mm	e.g.	Hahn und Kolb Borsigstraβ 50 D-7000 Stuttgart 30 Order no. G 222 K
Quick-callipers for internal measurements, dia. 60 - 80 mm		Order no. G 322 K
Micrometer 25 - 50 mm		Order no. 31346 025
Micrometer 50 - 75 mm		Order no. 31346 050

NOTE: Self-locking stud bolts are screwed into the crankcase for securing the crankshaft bearing caps. These stud bolts may only be used once as the locking adhesive applied over approx. 8 mm length of the thread is no longer effective when they are removed.

Pay attention to the different insertion depth and collar dia. when replacing the stud bolts.

When performing repairs, no HELI-COIL inserts may be used for the self-locking stud bolts of the crankshaft bearing caps.

Fig 5: Locating Self-Locking Stud Bolts

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The 5 crankshaft bearing caps manufactured from malleable cast iron are fitted into the side in the crankcase (arrows).

The fitting face (arrows) is positioned off-centre so that the bearing caps can only be installed in one position.

The three center bearing caps are additionally bolted to the housing side walls.

The crankshaft bearing caps are machined together with the crankcase and are not available as a replacement part.

Fig 6: Locating Crankshaft Bearing Caps From Crank Case Length

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

If bearing damage has occurred, the conrods must be removed and any swarf removed from the conrod bores and the oil passages of the crankshaft.

Carefully clean the oil passages in the crankcase, crankshaft, timing case cover, oil filter housing, closing cover, oil pump etc.

Examine crankshaft for cracks, dimensional tolerance and hardness (03-3180) .

Matching crankshaft bearings, installing crankshaft

Install crankshaft bearing caps, pay attention to marking, 1 is to the front.
The fit face is asymmetrical (arrows); the crankshaft bearing caps can thus only be installed in one position.
Oil thread and contact surface of nuts, tighten nuts to 50 Nm.
Oil thread and head contact surface of side bolts (M10 X 40), install with the washers and tighten to 50 Nm.

Fig 7: Locating Crankshaft Bearing Caps From Crank Case Length
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure crankshaft bearing bore in direction A, B and C at two levels (conicity); note measured values.
If a crankshaft bearing bore exceeds the specified value or is conical, dress bearing cap at its mating surface on a dressing plate up to max. 0.02 mm.

Fig 8: Identifying Crankshaft Bearing Bore Dimensions
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert bearing shells, install crankshaft bearing cap.
Tighten nuts and side bolts to 50 Nm.

Fig 9: Identifying Bearing Shells And Crankshaft Bearing Cap
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure bearing diameter and note.

Fig 10: Measuring Bearing Diameter
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure crankshaft bearing journals, determine radial play of crankshaft bearing.
NOTE: The bearing play can be connected by replacing the bearing shells (see table Matching crankshaft bearing shells to crankcase); in this case, aim for the average value of the bearing play stated.

Fig 11: Measuring Crankshaft Bearing Journals
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure width of fit bearing journal and of fit bearing. Determine axial play of crankshaft.
The fit bearing shells of the repair sizes are supplied oversized.

Fig 12: Measuring Width Of Fit Bearing Journal And Fit Bearing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Moisten bearing shells and crankshaft with SAE 30 engine oil and insert crankshaft.

Install bearing shells with oil drilling into the crankcase.

Fig 13: Identifying Crankcase, Fit Bearing And Crankshaft
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil the thread and the bolt head or nut contact surface for this step.
Nuts 50 Nm.

Side bolts 50 Nm

NOTE: Bolts of quality 10.9 should be used for the side bearing cap fixture.

Fig 14: Identifying Crankshaft Bearing Caps Tightening Diagram
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure axial play of crankshaft.
Rotate crankshaft by hand and check whether it runs freely.

Fig 15: Measuring Axial Play Of Crankshaft
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Matching conrod bearings and installing
Examine conrod bolts (03-3100) .
Repair and align conrod (03-3130) .

Fig 16: Examining Conrod Bolts
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert conrod bearing shells, install conrod bearing caps with conrod bearing shells and tighten conrod nuts or bolts to 35 Nm.
Measure bearing diameter and note.
Measure conrod bearing journal. Determine radial play of conrod bearing.
NOTE: The bearing play can be corrected by replacing the conrod bearing shells; if this step is performed, aim for the average value of the specified bearing play.

Crankshaft bearing shells without color coding are thicker than those with blue color coding, although it should be noted that the wall thicknesses without and with color coding may overlap.

Fig 17: Identifying Radial Play Of Conrod Bearing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install pistons and conrod (03-3160) .
Moisten bearing shells, crankshafts, pistons and cylinders with SAE 30 engine oil. Install conrod with pistons (03-3160) .

Pay attention to marking.

Install the bearing shells with the oil drilling in the conrod otherwise the conrod bushes will not be lubricated.

Fig 18: Locating Bearing Shells
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Tighten conrod nuts and conrod bolts (03-3100) .

Fig 19: Tightening Conrod Nuts And Conrod Bolts
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure axial play of conrod bearings. Examine clearance of conrod in the piston.

Disassemble oil pump, clean, renew if necessary. Replace oil delivery valve. Clean oil filter, carefully clean air-to-oil cooler or replace.

Install initial operation oil filter element. Change engine oil and oil filter element after 1000 - 1500 km.

Fig 20: Measuring Axial Play Of Conrod Bearings
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.