Remove/install crankshaft - AR03.20-P-4351GZ: Notes

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ENGINE 113.964 in MODEL 164.175

Fig 1: Identifying Crankshaft Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
		External Torx set	Figure
	Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	When moving components, ensure that no body parts or limbs are within the operating range of moving parts.	AS00.00-Z-0011-01A
1	Open engine hood and raise to vertical position		AR88.40-P-1000GZ
	Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and goggles. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
2	Disconnect ground cable from battery	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.	AR54.10-P-0003GZ
	Notes on battery	All models	AH54.10-P-0001-01A
	Risk of death caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
3	Raise vehicle with lifting platform		AR00.60-P-1000GZ
4	Remove engine compartment paneling		AR61.20-P-1105GZ
5	Remove engine		AR01.10-P-2400GZ
6	Remove automatic transmission from the engine		AR27.10-P-0500GZ
7	Remove oil pan bottom section		AR01.45-P-7555GZ
8	Dismount oil pan		AR01.45-P-7500GZ
9	Remove oil pump	For this step, push back chain tensioner and take off chain.	AR18.10-P-6020GZ
10	Remove belt pulley / vibration damper		AR03.30-P-1600GZ
11	Remove driven plate		AR03.30-P-8001GZ
12	Dismount end cover from the crankcase		AR01.40-P-8913GZ
13	Remove timing case cover		AR01.40-P-8000GZ
14	Remove connecting rod bearing cap (16)	While turning the crankshaft, ensure that the connecting rods (11) do not get jammed. For this step, mark connecting rod (11) and connecting rod bearing cap on one side relative to each other.
15	Take off crankshaft bearing caps (4, 10)	Follow release schematic, see: ↓ Tightening diagram of crankshaft bearing caps	AR03.20-P-4351-02BV
16	Carefully pry out the crankshaft bearing caps (4, 10) and the fitted bearing (5).	Mark crankshaft bearing cap and fitted bearing before removal. Lever out crankshaft bearing cap and fitted bearing carefully.
17	Take crankshaft (1) out of the crankcase
18	Take crankshaft bearing shells (2) and thrust washers (6) out of the crankcase
	Installing
19	Insert crankshaft (1)	Oil the crankshaft journals and crankshaft bearing shells.
		If a new crankshaft is being installed	AR03.20-P-4341-01VT
		If crankshaft is being repaired	AR03.20-P-4341-01VTA
		Main bearing play	*BE03.20-P-1001-04E
20	Take off crankshaft bearing caps (4, 10)	The crankshaft bearing cap bolts must always be replaced otherwise there is a risk of cranks and fracture.
		Tighten all bolts according to the tightening diagram.	AR03.20-P-4351-02BV
			*BA03.20-P-1001-01D
			*BA03.20-P-1002-01D
			*BA03.20-P-1003-01D
		Torque wrench	Fig 5
21.1	Check axial play of crankshaft	If a new crankshaft is being installed	AR03.20-P-4291-03VT
		Main bearing play	*BE03.20-P-1001-04E
		Connecting rod bearing play	*BE03.20-P-1002-04E
		Dial indicator holder	Figure
		Dial indicator	Figure
22	Inspect the connecting rod bolts (12)	Test data: ↓	AR03.10-P-6111-01VT
		Connecting rod bolts	*BE03.10-P-1001-03A
23	Install the connecting rod bearings and fit the connecting rod bearing cap (16)	The connecting rod bearing shell (13) with the oil drilling (arrow) must be installed in the connecting rod (11) otherwise the piston pins will not be greased. The anti-twist lock (14) on the connecting rod bearing shell (13) must be located in the grooves (15) of the connecting rods (11) and of the connecting rod bearing cap (16). 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 the accuracy of fit would no longer be given.	AR03.10-P-6111-06VT
		Connecting rod bearing play	*BE03.20-P-1002-04E
24	Tighten connecting rod bolts (12)		AR03.10-P-6111-02VT
			*BA03.10-P-1001-01E
		Torque wrench	Fig 5
		External Torx set	Figure
25	Turn crankshaft (1) to check for unobstructed movement.
26	Fit bolt for end cover to crankcase	Replace radial sealing ring. The sealing lip of the radial sealing ring and its mating surface must not be oiled or greased.	AR01.40-P-8913GZ
27	Install driven plate		AR03.30-P-8001GZ
28	Install timing case cover	Replace O-rings and radial sealing ring.	AR01.40-P-8000GZ
29	Install belt pulley/vibration damper		AR03.30-P-1600GZ
30	Install oil pump	Ensure oil return flow check valve is correctly located.	AR18.10-P-6020GZ
31	Fit oil pan		AR01.45-P-7500GZ
32	Fit oil pan bottom section		AR01.45-P-7555GZ
33	Check engine valve timing		AR05.10-P-6858GZ
34	Mount automatic transmission on engine		AR27.10-P-0500GZ
35	Install engine		AR01.10-P-2400GZ
	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 running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
36	Conduct engine test run and check the engine for leaks while it is running	In the event of oil loss determine and eliminate cause, otherwise malfunctions, transmission damage, and serious environmental pollution may occur.

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.		-

CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 112 except 112.951/976, Engines 113.940/941/ 942/943/944/ 948/960/961/ 963/964/965/ 966/967/968/ 971/980/981/ 984/986
BE03.20-P-1001-04E	Main bearing play	radial when new	mm	0.026 to 0.050
BE03.20-P-1001-04E	Main bearing play	axial when new	mm	0.10 to 0.266
BE03.20-P-1002-04E	Connecting rod bearing play	radial when new	mm	0.022 to 0.067

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

CRANKSHAFT BEARING CAP

Number	Designation				Engines 112, 113
BA03.20-P-1001-01D	Crankshaft bearing cap bolt	M8	Stage 1	Nm	20
BA03.20-P-1001-01D	Crankshaft bearing cap bolt	M8	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

Fig 2: Identifying External Torx Set (001 589 76 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Dial Indicator (001 589 32 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Dial Indicator Holder (363 589 02 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Torque Wrench (001 589 72 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.