Install/gauge crankshaft bearings - AR03.20-P-4341-01AMG (ML63 AMG)

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CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 156
BE03.20-P-1001-04E	Main bearing play	Radial measurement when new	mm	0.022 to 0.041
BE03.20-P-1001-04E	Main bearing play	Axial measurement when new	mm	0.15 to 0.316

CHECK VALUES FOR CRANKSHAFT

Number	Designation				Engine 156
	BE03.20-P-1001-02I	Crankshaft journal dia.	Nominal dia.	mm	67.950 to 67.965
Repair stage 1			Blue (B)	mm	67.962 to 67.965
Repair stage 2			Yellow (y)	mm	67.958 to 67.962
Repair stage 3			Red (R)	mm	67.954 to 67.958
Repair stage 4			Green (g)	mm	67.950 to 67.954
BE03.20-P-1002-02I	Crankshaft journal width at fit bearing	Marking	N/0	mm	27.900 to 29.933
BE03.20-P-1002-02I	Crankshaft journal width at fit bearing	Marking	N1/1	mm	28.000 to 28.033

CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number	Designation			Engine 156
	BE03.20-P-1004-03J	Main bearing shells standard dimension for crankcase and bearing cap(s) Ø67.950/67.966 mm	Replacement part additional number color coding green (g)=4	59
Bearing shell thickness	BE03.20-P-1004-03J		mm	2.267 to 2.271

CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number	Designation			Engine 156
	BE03.20-P-1002-03J	Main bearing shells standard dimension for crankcase and bearing cap(s) Ø67.950/67.966 mm	Replacement part additional number colored marking Yellow (y)=2	54
Bearing shell thickness	BE03.20-P-1002-03J		mm	2.259 to 2.263

CHECK VALUES FOR CRANKSHAFT

Number	Designation				Engine 156
BE03.20-P-1002-02I	Crankshaft journal width at fit bearing	Marking	N/0	mm	27.900 to 29.933
BE03.20-P-1002-02I	Crankshaft journal width at fit bearing	Marking	N1/1	mm	28.000 to 28.033

CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number	Designation			Engine 156
	BE03.20-P-1003-03J	Main bearing shells standard dimension for crankcase and bearing cap Ø67.950/67.966 mm	Replacement part additional number colored marking red (r)=3	56
Bearing shell thickness	BE03.20-P-1003-03J		mm	2.263 to 2.267

CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number	Designation			Engine 156
	BE03.20-P-1001-03J	Main bearing shells standard dimension for crankcase and bearing cap(s) Ø67.950/67.966 mm	Replacement part additional number colored marking blue (b)=1	52
Bearing shell thickness	BE03.20-P-1001-03J		mm	2.255 to 2.259

CRANKSHAFT BEARING CAP

Number	Designation				Engine 156
BA03.20-P-1001-01J	Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	M9	Stage 1	Nm	20
			Stage 2	Nm	32
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5		release
			Stage 6	Nm	20
		Stage 7		Nm	32
		Stage 8		∠°	90
		Stage 9		∠°	90
		M10	Stage 1	Nm	20
			Stage 2	Nm	40
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5	release
			Stage 6	Nm	20
			Stage 7	Nm	40
			Stage 8	∠°	90
			Stage 9	∠°	90
BA03.20-P-1002-01J	Cylinder crankcase lower part to cylinder crankcase upper part	M6	Stage 1	Nm	4
		M6	Stage 2	∠°	90
		M8	Stage 1	Nm	10
		M8	Stage 2	∠°	90

Fig 1: Installing/Gauging Crankshaft Bearings (1 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Installing/Gauging Crankshaft Bearings (2 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Installing/Gauging Crankshaft Bearings (3 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Installing/Gauging Crankshaft Bearings (4 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1. Blow out oil ducts with compressed air.

2. Clean bearing points in cylinder crankcase upper section, main bearing cap or cylinder crankcase lower section and main bearing journal on crankshaft with chamois leather.

If a bearing damage has occurred, it may be necessary to remove any debris from the connecting rod bores, oil ducts on the crankshaft as well as the cylinder crankcase. Do not use any hard objects for cleaning.

Assignment of the upper bearing shell halves to the basic journal of the crankshaft occurs via color markings on the rear side of the upper bearing shell halves and numbers on the upper cylinder crankcase (see picture). Only the assigned letter and number combinations should be fitted together.

3. Insert upper bearing shell halves (1) with the oil holes (2) and the oil grooves (3) in the cylinder crankcase upper section (7).

Ensure that the anti-twist locks (4) on the upper crankshaft bearing shell halves (1) are seated in the cutouts of the cylinder crankcase upper section (7).

4. Insert lower bearing shell halves into bearing cap or cylinder crankcase lower section (8).

Ensure that the anti-twist locks on the lower bearing shell halves are seated in the recesses for the bearing cap or the cylinder crankcase lower section (8).

5. Insert crankcase (15) into cylinder crankcase upper section (7).

6. Install upper thrust plates.

The oil grooves on the thrust plates must point to the crank webs.

7.1 ENGINE 156: Install bearing caps according to their markings.

When installing the fitted bearing cap firmly hold both thrust plates. The anti-twist locks of the thrust plates must sit in the grooves of the fitted bearing cap. The oil grooves of the thrust plate must point towards the crank webs.

7.2 ENGINE 159: When installing cylinder crankcase lower section (8), hold both thrust plates. The anti-twist locks of the thrust plates must sit in the grooves. The oil grooves of the thrust plate must point towards the crank webs.

8. Moisten screw/bolts on bearing cap or cylinder crankcase bottom section (8) on thread and bolt head contact surface with oil.

9. Tighten screw/bolts according to tightening procedure.

Observe torque and tightening angle of screw/ bolts.

10. Turn crankshaft (15) to check for unobstructed movement.