Remove/install crankshaft - AR03.20-P-4351AMG (ML63 AMG): Notes

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ENGINE 156.980 /982 /983 /984

Fig 1: Identifying Crankshaft Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Crankshaft Bottom Section And Bolts

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	Risk of death caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1.1	Remove engine with front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2500GZS
1.2	Remove engine	Engine 156.982 in model 209	AR01.10-P-2400QMG
		Engine 156.983 in model 211, 219	AR01.10-P-2400TMG
		Engine 156.984 in model 216, 221	AR01.10-P-2400SMG
2	Remove engine from front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2510GZS
3	Detach transmission from the engine
4	Remove oil lines from automatic transmission at oil pan
5	Mount engine onto assembly stand
6	Remove spark plugs	Only if it is not possible to crank engine due to high compression.
		Model 164, 251	AR15.12-P-1010GZS
		Model 209, 211, 219	AR15.12-P-1010TMG
		Model 216, 221	AR15.12-P-1010SMG
7	Turn engine at crankshaft (5) in direction of engine rotation to a 40° crank angle after ignition TDC and check position of camshafts	Rotate engine at crankshaft (5) in running direction until the 40° marking on pulley/ vibration damper corresponds with marking on timing case cover.	AR05.20-P-6010-01AMG
8	Remove timing case cover	Do not damage cylinder head gaskets. Leaks and engine damage can occur otherwise.	AR01.40-P-8000AMG
9	Remove flywheel/drive plate	Model 164, 251	AR03.30-P-8001GZS
		Model 209, 211, 219	AR03.30-P-8001TMG
		Model 216, 221	AR03.30-P-8001SMG
10	Remove oil pump	Model 164, 251	AR18.10-P-6020GZS
		Model 209, 211, 219	AR18.10-P-6020TMG
		Model 216, 221	AR18.10-P-6020SMG
11	Remove oil pump chain (6)
12	Remove vacuum reservoir (7) at crankcase upper section (11)	On vehicles with vacuum reservoir (7) at cylinder crankcase upper section (11).
13	Detach both engine supports (12)
14	Loosen bolts (14, 15) from crankcase bottom section (13) in reverse order of tightening procedure	Installation: Lubricate bearing shells and check for unobstructed movement of crankshaft (5) by turning.
		Tightening procedure for crankcase bottom section	AR03.20-P-4351-05AMG
	Information on application of sealant to crankcase bottom section		AH01.40-P-1000-03AMG
			*BA03.20-P-1001-01J
			*BA03.20-P-1002-01J
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
		Application gun	Fig 3
15	Place match marks for connecting rod (1) and connecting rod bearing cap (2) (arrow)	The connecting rods (1) are cracked during production. The connecting rod bearing caps (2) are not interchangeable and cannot be fitted laterally reversed.
16	Remove connecting rod bearing cap (2)	Connecting rod bolts must be replaced. The previously installed connecting rod bolts must not be installed again. This is because for reusing loosening can occur and associated engine damage can occur. Assign connecting rod bearing cap (2) and lower connecting rod bearing shells (3) to each other. Mark connecting rod (1) and upper connecting rod bearing shells (4) relative to each other. While rotating the crankshaft (5) ensure that connecting rods (1) do not tilt. Installation: Lubricate the bearing shells and turn the crankshaft (5) to check that it moves freely. Installation: Install and measure connecting rod bearings. Installation: Tighten connecting rod bolts according to tightening specification.
		Install and gauge connecting rod bearings	AR03.10-P-6111-06VA
		Tighten connecting rod bolts	AR03.10-P-6111-02AMG
		Connecting rod bearing play	*BE03.20-P-1002-04E
		Connecting rod bearing cap on connecting rod	*BA03.10-P-1001-01Q
17	Remove rear crankshaft radial sealing ring	The installation takes place before mounting the flywheel/drive plate.	AR03.20-P-3063-01AMG
	Installation tool	Fig 4	AR03.20-P-3063-01AMG
18	Take crankshaft (5) out of crankcase top section (11)	Take out upper crankshaft-bearing shells (8) and thrust plates (9) from cylinder crankcase upper section (11). Mark thrust plates (9) relative to crankshaft fitted bearing. Note bearing play. Installation: Check upper crankshaft bearing shells (8) and bottom crankshaft bearing shell (10) for wear.	AR03.20-P-4341-01AMG
		Main bearing play	*BE03.20-P-1001-04E
		Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm	*BE03.20-P-1001-03J
		Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm	*BE03.20-P-1002-03J
		Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm	*BE03.20-P-1003-03J
		Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm	*BE03.20-P-1004-03J
		Crankshaft journal dia	*BE03.20-P-1001-02I
		Crankshaft journal width at fit bearing	*BE03.20-P-1002-02I
		Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	*BA03.20-P-1001-01J
		Cylinder crankcase lower part to cylinder crankcase upper part	*BA03.20-P-1002-01J
19	Remove sealant	Do not use any sharp-edged tools or abrasive paper. The sealing surfaces will be damaged otherwise.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
20	Install in the reverse order
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
21	Perform an engine test run and check engine for leaktightness

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-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
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
BE03.20-P-1002-03J		Bearing shell thickness	mm	2.259 to 2.263
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
BE03.20-P-1003-03J		Bearing shell thickness	mm	2.263 to 2.267
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
BE03.20-P-1004-03J		Bearing shell thickness	mm	2.267 to 2.271

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
BE03.20-P-1002-04E	Connecting rod bearing play	Radial measurement when new	mm	0.028 to 0.063

CONNECTING ROD

Number	Designation			Engine 156
BA03.10-P-1001-01Q	Connecting rod bearing cap to connecting rod	Stage 1	Nm	10
		Stage 2	Nm	40
		Stage 3	∠°	90

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 3: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Installation Tool (111 589 08 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite 5970 sealant	A 003 989 98 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49 899268-0 Fax +49 899101978 www.Loctite.de
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150ml)	A 001 986 71 71 10