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

ENGINE 601, 602, 603 (except 602.98) 

Shown on engine 601 

IMPORTANTThe 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
G05438251Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Remove    
1 Remove crankshaft TORQUE SPECIFICATION *BA03.20-P-1001-01A 
    IMPORTANTInstallation  : Inspect length of bolt of crankshaft bearing cap, replace if necessary (2nd version)
TORQUE SPECIFICATION		 *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 NOTES 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 Inspect     
3 Inspect conrod, repair if necessary NOTES 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 NOTES 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 
    TORQUE SPECIFICATION Crankshaft bearing cap *BA03.20-P-1001-01A 
    TORQUE SPECIFICATION Conrod bolt *BA03.10-P-1001-01C 
    TORQUE SPECIFICATION Conrod bolt *BA03.10-P-1002-01C 
    SPECIAL TOOL Figure
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1012-12A 
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1001-12A 
    IMPORTANT
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 
    TORQUE SPECIFICATION Crankshaft bearing cap *BA03.20-P-1001-01A 
    SPECIAL TOOL Figure
    SPECIAL TOOL Figure
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1012-12A 
    COMMERCIALLY AVAILABLE TOOLS *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
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
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
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
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
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
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
TORQUE SPECIFICATION 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
2nd stage ∠ ° 90
BA03.20-P-1002-01A Bolt of crankshaft bearing M12   Nm 90
TORQUE SPECIFICATION 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
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)
G05438252Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Dial Gage Holder (363 589 02 21 00)
G05438253Courtesy 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
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