Mounting crankshaft in bearings - RA030B1193200X(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

B. Engine 119.97/98 with thrust washers

Fig 1: Exploded View Of Crankshaft Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

DATA M119.971/975/981/985

Crankshaft standard size and repair sizes

Crankshaft bearing journal Ø

Color coding

Thickness of thrust washers at fit bearing

Crankshaft journal width at fit bearing

Crankshaft bearing journal Ø

Crankshaft bearing journal width

Standard size

63.960 ⁽¹⁾

→

blue

2.20 ⁽²⁾

27.000

47.965

50.000

63.965

yellow

27.033

47.955

50.100

63.955 ⁽¹⁾

→

red

2.25⁽²⁾

63.960

63.950 ⁽¹⁾

→

2.30⁽²⁾

63.955

Standard size, I

63.945

63.950

63.940

63.945

63.935

63.940

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

⁽²⁾	Crankshaft main bearing with thrust washers as of engine no. 119.970 12 036277 119.971 12 017447 119.972 12 004797 119.974 12 008072 119.975 12 010516 119.98 as of start of production

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

Crankcase

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⁽²⁾

0.030-0.055⁽²⁾

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⁾	Aim for the 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 chisel point	2 chisel points	3 chisel points
Colored dots on crankshaft bearing cap	blue	yellow	red
Color of top bearing shell	blue	yellow	red
	Matching bottom bearing shell with color coding
Color coding on crankshaft	blue	yellow	red
Color of bottom bearing shell	blue	yellow	red

The top and bottom standard size crankshaft bearing shells are supplied as replacement parts with the color codings blue, yellow and red. They should be matched according to the table. It is then no longer necessary to gage the bearing clearances.

Fig 2: Locating Crankshaft Bearing Shells

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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 should therefore be used only once.

Special tools

Fig 3: Identifying Special Tools (001 589 72 21 00)

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

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Fig 5: Identifying Special Tools (363 589 02 21 00)

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COMMERCIALLY AVAILABLE TOOLS

Quick calipers for internal measurements, Ø 40 -60 mm	e.g.	Hahn und Kolb Borsigstraβe 50 D-7000 Stuttgart 30 Order no. G 222 K
Quick calipers for internal measurements, Ø 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 inserted into the crankcase for attaching the crankshaft bearing caps. The stud bolts should only be used once as the locking fluid applied over a length of about 8 mm of the thread is rendered ineffective when the bolts are unscrewed.

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

When performing repairs, do not use HELI-COIL inserts for the self-locking stud bolts of the crankshaft bearing caps.

Fig 6: Locating Self-Locking Stud Bolts

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The 5 crankshaft bearing caps are manufactured from malleable cast iron and are interference fitted in the side of the crankcase (arrows). The fit (arrows) is off-centered with the result that the bearing caps can only be installed in one position.

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

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

Fig 7: Locating Crankshaft Bearing Caps From Crank Case Length

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Standard bearing shells and thrust washers are installed at the 3rd crankshaft bearing (fit bearing).

The thrust washers absorb the axial forces of the crankshaft.

The thrust washers (13 and 14) inserted on both sides of the crankcase and the bearing cap, are identical.

The thrust washers in the bearing cap each have identical.

The thrust washers in the bearing cap each have two retaining lugs, the bottom lugs being positioned off-center, as an anti-twist lock and to avoid incorrect installation. In addition, all the thrust washers are chamfered at one end. The two oil grooves in the thrust washers must face towards the crank webs.

When repairing crankshafts, the fit bearing journals should be re-ground in width to one of the dimensions stated in the table (section "Data").

After bearing damage has occurred, the conrod should be taken out and any swarf present in the conrod bores and in the crankshaft oil galleries, removed.

Carefully clean oil galleries in crankcase, crankshaft, timing case cover, oil filter housing, end cover, oil pump etc.

Inspect crankshafts for cracks, dimensional tolerance and hardness.

Fig 8: Identifying Crankshaft And Crankshaft Bearing

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Matching crankshaft bearings, installing crankshaft

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

Fig 9: Locating Crankshaft Bearing Caps From Crank Case Length
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure crankshaft bearing bore in the direction A, B and C at two planes (conicity) and note the measurements obtained.
If a crankshaft bearing bore exceeds the specified data or is conical in shape, dress the contact surface of the bearing cap on a dressing plate to not more than 0.02 mm.

Fig 10: Identifying Crankshaft Bearing Bore Dimensions
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert bearing shells and install crankshaft bearing cap.
Tighten nuts and side bolts to 50 Nm.

Fig 11: Identifying Crankshaft Bearing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure bearing diameter and note.

Fig 12: Measuring Bearing Diameter
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure crankshaft bearing journal and determine radial crankshaft bearing play.
NOTE: The bearing play can be corrected by replacing the bearing shells (see table Matching crankshaft bearing shells to crankcase).

Fig 13: Measuring Crankshaft Bearing Journal And Determine Radial Crankshaft Bearing Play
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measure width of fit bearing journal and of fit bearing and determine axial crankshaft bearing play.
(See table of Data)

The repair size fit bearing shells are supplied oversized.

Fig 14: Measuring Width Of Fit Bearing Journal
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 in the crankcase.
Oil thrust washers with engine oil and push into the grooves at the fit bearing (crankcase).

Fig 15: Installing Bearing Shells
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Install fit bearing cap.

Hold both thrust washers tight when installing the fit bearing cap.

Fig 16: Installing Bearing Cap
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The two oil grooves (arrows) in the thrust washers must face toward the crank webs.
Install crankshaft bearing caps.

Fig 17: Locating Crankshaft Bearing Caps
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Tighten crankshaft bearing caps to the specified torque in the order of the tightening diagram. Oil the thread and the bolt head and 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 connection.

Fig 18: Locating Crankshaft Bearing Caps Tightening Diagram
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Measure crankshaft bearing axial play.
Rotate crankshaft by hand and check whether it rotates freely.

Fig 19: Measuring Crankshaft Bearing Axial Play
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Matching conrod bearings and installing
Inspect conrod bolts (03-3100) .
Repair conrod and align (03-3130) .

Fig 20: Inspecting Conrod Bolts
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Insert conrod bearing shells, install conrod bearing caps with conrod bearing shells and tighten conrod nuts and bolts to 35 Nm.
Measure bearing diameter and note.
Measure conrod bearing journals and determine conrod bearing radial play.
NOTE: The bearing play can be corrected by replacing the conrod bearing shells. Aim for the average value of the bearing play stated.

Conrod bearing shells without color coding are thicker than those with blue color coding; note, however, that the wall thicknesses with and without color coding may overlap.

Fig 21: Identifying Bearing Diameter
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Assemble 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 identification.

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

Fig 22: Locating Conrod Bearing Shells
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Tighten conrod bolts (03-3100) .

Fig 23: Tightening Conrod Bolts
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Measure conrod bearing axial play. Inspect clearance of conrods in piston.

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

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

Fig 24: Measuring Conrod Bearing Axial Play
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.