LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 1996 >> E320 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Crank Assembly - Testing & Repair - 210 Chassis >> Testing & Repair >> Remove/install crankshaft - AR03.20-P-4351AV

Remove/install crankshaft - AR03.20-P-4351AV

ENGINE 112 

Fig 1: Identifying Crankshaft, Crankshaft Bearing Shell
G04605705Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Modification notes

27.2.04 Figure modified from 30 Nm and 90 ≤° to 5 Nm, 30 Nm and 90 ≤° Figure in BA03.20-P-1003-01D of ENGINE 112, 113 modified *BA03.20-P-1003-01D 
REMOVING Removing    
DANGER Risk of death  caused by vehicle slipping or toppling off the lifting platform. Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
1 Remove engine Model 463 AR01.10-P-2400CC
Model 220 without 4MATIC AR01.10-P-2400AB
Model 220 with 4MATIC AR01.10-P-2400IW
Model 210 with 4MATIC AR01.10-P-2400C
Model 210 without 4-MATIC, 208, 202, 129 AR01.10-P-2400CB
Models 211.061/065 AR01.10-P-2400TC
Model 203 without 4MATIC, 209 AR01.10-P-2400PV
Model 203 with 4MATIC AR01.10-P-2400PW
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
2.1 Remove automatic transmission from engine Model 463 AR27.10-P-0500BD
Model 220 without 4MATIC AR27.10-P-0500I
Model 220 with 4MATIC AR27.10-P-0500IW
Models 210, 208, 202, 170, 129 AR27.10-P-0500B
Models 211.061/065 AR27.10-P-0500T
Model 203 without 4MATIC, 209 AR27.10-P-0500P
Model 203 with 4MATIC AR27.10-P-0500PW
Model 163 AR27.10-P-0500GH
2.2 Remove manual transmission from engine Models 210,202, 129 AR26.10-P-0020A
Model 211.061 AR26.10-P-0020T
MODEL 203, 209 AR26.10-P-0020P
Model 170 AR26.10-P-0020D
Model 208 with transmission 716.6 AR26.10-P-0020D
Model 208 with transmission 716.6 (code 424) AR26.10-P-0020E
3 Remove oil pan top section Model 463 AR01.45-P-7500FG
Model 220 without 4MATIC AR01.45-P-7500I
Model 220 with 4MATIC AR01.45-P-7500IW
Model 210 with 4MATIC AR01.45-P-7500FA
Model 210 without 4MATIC AR01.45-P-7500F
Models 211.061/065 AR01.45-P-7500TV
Models 208, 202 AR01.45-P-7500FC
Model 203 without 4MATIC, 209 AR01.45-P-7500PV
Model 203 with 4MATIC AR01.45-P-7500PW
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
4 Remove oil pump IMPORTANT For this step, push back chain tensioner and take off chain.  
Models 129, 163, 170, 202, 208.365/465, 210, 220 without 4MATIC, 463 AR18.10-P-6020B
Model 203 without 4MATIC, 209, 211.061/065 AR18.10-P-6020PV
Model 203 with 4MATIC, 220 with 4MATIC AR18.10-P-6020PW
5 Detach belt pulley/vibration damper Models 129, 463, 163 AR03.30-P-1600C 
Model 170, 202, 203, 208.365/465, 209, 210, 211.061/065,220 AR03.30-P-1600CA 
6 Detach flywheel/driven plate   AR03.30-P-8001C 
7 Take off end cover   AR01.40-P-8913B
8 Take off timing case cover MODEL 463 AR01.40-P-8000GV
Models 220, 210 without 4-MATIC, 208, 202, 129, 163, 170 AR01.40-P-8000B
Model 210 with 4MATIC AR01.40-P-8000V
Models 203, 209, 211.061/065 AR01.40-P-8000PV
9 Remove connecting rod bearing cap (16) IMPORTANT While turning the crankshaft, ensure that the connecting rods (11) do not get jammed.
IMPORTANT For this step, mark connecting rod (11)and connecting rod bearing cap (16) on one side relative to each other.		  
10 Unscrew the crankshaft bearing cap bolts IMPORTANT Pay attention to the bolt release pattern: ↓ Bolt tightening pattern for crankshaft bearing cap(s) AR03.20-P-4351-02AV 
11 Remove the crankshaft bearing caps (4, 10) and fitted bearing (5) IMPORTANT Before removing, mark the crankshaft bearing caps (4, 10) and fitted bearing (5). Carefully lever out crankshaft bearing caps (10) and (5).  
12 Take crankshaft (1) out of the crankcase    
13 Take crankshaft bearing shells (2) and thrust washers (6) out of the crankcase    
INSTALLING Install     
14 Insert crankshaft (1) IMPORTANT Oil crankshaft journals and crankshaft bearing shells (2)  
If a new crankshaft is being installed AR03.20-P-4341-01CV 
If crankshaft is being repaired AR03.20-P-4341-01CVA 
15 Tighten the crankshaft bearing caps NOTES The crankshaft bearing cap bolts M8X75 and M10X90 must always be replaced otherwise there is a risk of cranks and fracture. Tighten all bolts (M10, M8) at the same time, as specified in the tightening diagram.  
    Tightening pattern AR03.20-P-4351-02AV 
    TORQUE SPECIFICATION Bolt (7) *BA03.20-P-1001-01D 
TORQUE SPECIFICATION Side bolt (9) *BA03.20-P-1002-01D 
TORQUE SPECIFICATION Bolt (8) *BA03.20-P-1003-01D 
16.1 Check axial play of crankshaft If a new crankshaft is being installed AR03.20-P-4291-03AV 
17 Inspect the connecting rod bolts (12) MEASURING Test data: ↓
Thread and shank length		 AR03.10-P-6111-01BV 
*BE03.10-P-1001-03A 
18 Install the connecting rod bearings and fit the connecting rod bearing cap (16) NOTES The connecting rod bearing shell (13) with oil drilling (arrowed) must be mounted in the connecting rod (11), otherwise the connecting rod bearings will not be lubricated. The anti-twist locks (14) of the connecting rod bearing shells (13) must be located in the grooves (15) in the connecting rod (11) and the connecting rod bearing cap (16).
NOTES The connecting rod (11) and connecting rod bearing cap (16) are cracked (broken) (see zoomed section). They must not be installed on the wrong side, as dimensional accuracy would be lost.		 AR03.10-P-6111-06AV 
19 Tighten connecting rod bolts (12) TORQUE SPECIFICATION AR03.10-P-6111-02BV 
*BA03.10-P-1001-01E 
20 Rotate crankshaft IMPORTANT To check that it turns freely.  
21 Fit on end cover IMPORTANT Fit a new radial sealing ring. The sealing lip of the radial sealing ring and its mating surface must not be oiled or greased. Pay attention to the fitted sleeves when pressing on the end cover. AR01.40-P-8913B
22 Mount the flywheel/drive plate   AR03.30-P-8001C 
23 Mount the timing case cover IMPORTANT Replace the O-rings and radial sealing ring. The sealing lip of the radial sealing ring and its mating surface must not be oiled or greased. Pay attention to the fitted sleeves when pressing on the end cover.  
Model 463 AR01.40-P-8000GV
Models 220, 210 without 4-MATIC, 208, 202, 129, 163, 170 AR01.40-P-8000B
Model 210 with 4MATIC AR01.40-P-8000V
Models 203, 209, 211.061/065 AR01.40-P-8000PV
24 Mount belt pulley/vibration damper Models 129, 463, 163 AR03.30-P-1600C 
Model 170, 202, 203, 208.365/465, 209, 210, 211.061/065,220 AR03.30-P-1600CA 
25 Mount oil pump NOTES Ensure that the oil return shutoff valve is correctly located.
Clean oil pump strainer.
Fill oil pump with engine oil before installing, so that oil is delivered at the initial startup.		  
Models 129, 163, 170, 202, 208.365/465, 210, 220 without 4MATIC, 463 AR18.10-P-6020B
Model 203 without 4MATIC, 209, 211.061/065 AR18.10-P-6020PV
Model 203 with 4MATIC, 220 with 4MATIC AR18.10-P-6020PW
26 Fit oil pan top section Model 463 AR01.45-P-7500FG
Model 220 without 4MATIC AR01.45-P-7500I
Model 220 with 4MATIC AR01.45-P-7500IW
Model 210 with 4MATIC AR01.45-P-7500FA
Model 210 without 4MATIC AR01.45-P-7500F
Models 211.061/065 AR01.45-P-7500TV
Models 208, 202 AR01.45-P-7500FC
Model 203 without 4MATIC, 209 AR01.45-P-7500PV
Model 203 with 4MATIC AR01.45-P-7500PW
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
27 Check engine valve timing   AR05.10-P-6858V
28.1 Fit the automatic transmission Model 463 AR27.10-P-0500BD
Model 220 without 4MATIC AR27.10-P-0500I
Model 220 with 4MATIC AR27.10-P-0500IW
Models 210, 208, 202, 170, 129 AR27.10-P-0500B
Models 211.061/065 AR27.10-P-0500T
Model 203 without 4MATIC, 209 AR27.10-P-0500P
Model 203 with 4MATIC AR27.10-P-0500PW
Model 163 AR27.10-P-0500GH
28.2 Fit on manual transmission Models 129, 210, 202 AR26.10-P-0020A
Model 211.061 AR26.10-P-0020T
Model 203, 209 AR26.10-P-0020P
Model 170 AR26.10-P-0020D
Model 208 with transmission 716.6 AR26.10-P-0020D
Model 208 with transmission 716.6 (code 424) AR26.10-P-0020E
29 Install engine Model 463 AR01.10-P-2400CC
Model 220 without 4MATIC AR01.10-P-2400AB
Model 220 with 4MATIC AR01.10-P-2400IW
Model 210 with 4MATIC AR01.10-P-2400C
Model 210 without 4-MATIC, 208, 202, 129. AR01.10-P-2400CB
Models 211.061/065 AR01.10-P-2400TC
Model 203 without 4MATIC, 209 AR01.10-P-2400PV
Model 203 with 4MATIC AR01.10-P-2400PW
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
Check values for connecting rod bolts

Number Designation Engine 112 except 112.951/976, Engine 113.94/96/971/ 980/981/982/ 984/986
BE03.10-P-1001-03A Connecting rod bolts Thread dia. ø   M 8x1
Shank length When new mm 47
  max. mm 47.6
  Part no.   -
TORQUE SPECIFICATION Connecting rod

Number Designation Engines 112,113
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 25
Stage 3 ∠° 90
TORQUE SPECIFICATION Crankshaft bearing cap

Number Designation Engines 112,113
BA03.20-P-1001-01D Crankshaft bearing cap bolt M8 Stage 1 Nm 20
Stage 2 ∠° 90
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8   Nm 30
BA03.20-P-1003-01D Crankshaft bearing cap bolt M10 Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 ∠° 90
scientia non olet · About LEMON Manuals