Replace crankcase - AR01.40-P-8400AMG (ML63 AMG): Notes
WARNING: This page does not describe the selected car, but rather 28 other vehicles, including the 2012 Mercedes-Benz GL550, 2012 Mercedes-Benz GL450, 2011 Mercedes-Benz ML63, 2011 Mercedes-Benz ML550, and 2011 Mercedes-Benz ML350. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE 156
Fig 1: Identifying Upper/Lower Crankcase, Dowel Pins, Intermediate Gear Bearing Sleeve, And Right Knock Sensor 1
Fig 4: Identifying Upper Bearing Shell Halves, Oil Hole, Oil Groove, Anti-Twist Lock, Fitted Bolt And Oil Spray Nozzle
| Check | |||
| 1 | Check package contents for cylinder crankcase (7, 8) | The following parts are contained in the package contents: Piston with piston rings Upper bearing shell (1) Knock sensors (A16/1, A16/2) Crankshaft position sensor (L5) (except model 204) Crankshaft Hall sensor (B70) (model 204) Crankcase ventilation system (12) Stop plug (13) Oil thermostat Bearing sleeve intermediate gear (16) Dowel pins (10) for tensioning rails and slide rails |
|
| Remove | |||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| 2 | Remove pistons | AR03.10-P-7021AMG | |
| 3 | Detach connecting rods from piston | If reusing the connecting rods | |
| 4 | Remove timing case cover | AR01.40-P-8000AMG | |
| 5 | Remove tensioning rails and slide rails for the timing chain | AR05.10-P-8500GZS | |
| 6 | Take off timing chain | ||
| 7 | Detach intermediate gear for timing chain from the bearing sleeve (16) | Check intermediate gear for wear and damage; replace if necessary | |
| 8 | Detach right and left engine support from cylinder crankcase (7, 8) | AR22.10-P-1260GZS | |
| 9 | Remove crankshaft (15) | AR03.20-P-4351AMG | |
| 10 | Remove fit bolts (5) and oil spray nozzles (6) | The oil spray nozzles must be replaced if there is bearing damage. | AR18.00-P-4000AMG |
| 11 | Detach engine cable harness from cylinder crankcase (7, 8) | ||
| Clean | |||
| 12 | Clean sealing surfaces | Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise. |
|
| Loctite 7200 | *BR00.45-Z-1038-04A | ||
| Loctite 7063 cleaning spray (150 ml) | *BR00.45-Z-1046-04A | ||
| Install | |||
| 13 | Position oil spray nozzles (6) and screw in fit bolts (5) | AR18.00-P-4000AMG | |
| 14 | Install crankshaft (15) | AR03.20-P-4351AMG | |
| Mount crankshaft bearing and measure as required. | |||
| Install/gauge crankshaft bearings | 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 | ||
| Cylinder crankcase lower part to cylinder crankcase upper part | *BA03.20-P-1002-01J | ||
| Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection) | *BA03.20-P-1001-01J | ||
| Crankshaft journal width at fit bearing | *BE03.20-P-1002-02I | ||
| Crankshaft journal dia. | *BE03.20-P-1001-02I | ||
| Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm | *BE03.20-P-1004-03J | ||
| 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 crankcase and bearing cap Ø 67.950/67.966 mm | *BE03.20-P-1002-03J | ||
| 15 | Mount connecting rod on piston | Connecting rod bearing play | *BE03.20-P-1002-04E |
| 16 | Install pistons | AR03.10-P-7021AMG | |
| 17 | Mount right and left engine support on cylinder crankcase (7, 8) | AR22.10-P-1260GZS | |
| 18 | Detach centering sleeves on control side of the cylinder crankcase (7, 8) | ||
| 19 | Mount intermediate gear for timing chain with bearing sleeve (16) on the upper cylinder crankcase (7) | Replace intermediate gear cap. | |
| 20 | Install tensioning rails and slide rails for the timing chain | AR05.10-P-8500GZS | |
| 21 | Fit on timing chain | ||
| 22 | Mount engine cable harness on cylinder crankcase (7, 8) | Ensure correct routing of the motor cable harness on the cylinder crankcase. | |
| 23 | Install timing case cover | AR01.40-P-8000AMG | |
| Notes on sealant path for timing case cover | AH01.40-P-1000-01AMG | ||
| Replace crankshaft radial sealing ring, coolant passage seal, and radial sealing ring for oil centrifuge. Note different bolt lengths: |
|||
| Bolt plan for timing case cover | AR01.40-P-8000-01AMG | ||
| Bolt, coolant pump to timing case cover/crankcase | *BA20.10-P-1001-01V | ||
| Screw/bolt, timing case cover to cylinder crankcase | *BA01.40-P-1001-01W | ||
| Screw/bolt, cylinder head bolt to timing case cover chain box on outside | *BA01.40-P-1002-01W | ||
| Cylinder head to timing case chain box on inside | *BA01.40-P-1003-01W | ||
| Loctite 5970 sealant | *BR00.45-Z-1013-01A | ||
| Cleaner from the package | *BR00.45-Z-1028-04A | ||
| Application gun | Fig 5 | ||
| Drift | Fig 6 | ||
CHECK VALUES OF CRANKSHAFT
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BE03.20-P-1001-02I | Crankshaft journal diameter: | |||
| Nominal dia. Repair stage 1...............Blue (B) Repair stage 2...............Yellow (y) Repair stage 3...............Red (R) Repair stage 4...............Green (g) |
mm mm mm mm mm |
67, 950...67, 965 67, 962...67, 965 67, 958...67, 962 67, 954...67, 958 67, 950...67, 954 |
||
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1001-03J | Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm | Replacement part additional number, colored marking blue (b)=1 | 52 |
| Bearing shell thickness (mm) | 2, 255...2, 259 | ||
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1001-04E | Connecting rod bearing play | Radial measurement when new (mm) | 0, 022...0, 041 |
| Axial measurement when new (mm) | 0, 15...0, 316 | ||
CHECK VALUES OF CRANKSHAFT
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1002-02I | Crankshaft journal width at fit bearing: | ||
| Marking N/0 | mm | 27, 900...29, 933 | |
| Marking N1/1 | mm | 28, 000...28, 033 | |
CHECK VALUES OF CRANKSHAFT MAIN BEARING SHELLS
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1002-03J | Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm | Replacement part additional number (color coding yellow (y)=2 | 54 |
| Bearing shell thickness (mm) | 2, 259...2, 263 | ||
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1002-04E | Connecting rod bearing play | Radial measurement when new (mm) | 0, 028...0, 063 |
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1003-03J | Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm | Replacement part additional number, colored marking red (r)=3 | 56 |
| Bearing shell thickness (mm) | 2, 263...2, 267 | ||
CHECK VALUES OF CRANKSHAFT MAIN BEARING SHELLS
| Number | Designation | Engine 156 | |
|---|---|---|---|
| BE03.20-P-1004-03J | Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm | Replacement part additional number, color coding green (g)=4 | 59 |
| Bearing shell thickness (mm) | 2, 267...2, 271 | ||
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA01.40-P-1001-01W | Screw/bolt, timing case cover to cylinder crankcase | M8 | Nm | 20 |
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA01.40-P-1002-01W | Screw/bolt, cylinder head bolt to timing case cover chain box on outside | M8 | Nm | 20 |
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA01.40-P-1003-01W | Cylinder head to timing case chain box on inside | M8 | Nm | 20 |
CRANKSHAFT BEARING CAP
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA03.20-P-1001-01J | Bolt to crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection): | |||
| M9 | Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 Stage 9 |
Nm Nm ∠° ∠° - Nm Nm ∠° ∠° |
20 32 90 90 release 20 32 90 90 |
|
| M10 | Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7 Stage 8 Stage 9 |
Nm Nm ∠° ∠° - Nm Nm ∠° ∠° |
20 40 90 90 release 20 40 90 90 |
|
CRANKSHAFT BEARING CAP
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA03.20-P-1002-01J | Cylinder crankcase lower part to cylinder crankcase upper part: | |||
| M6 | Stage 1 Stage 2 |
Nm ∠° |
4 90 |
|
| M8 | Stage 1 Stage 2 |
Nm ∠° |
10 90 |
|
COOLANT PUMP, COOLANT THERMOSTAT
| Number | Designation | Engine 156 | ||
|---|---|---|---|---|
| BA20.10-P-1001-01V | Bolt, coolant pump to timing case cover/crankcase: | M6 X30 M6 X80 M8 X80 M8 X100 |
Nm Nm Nm Nm |
9 9 20 20 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1013-01A | Loctite sealant 5970 | A 003 989 98 20 |
| BR00.45-Z-1028-04A | Cleaner from package | Adolf Wurth GmbH & Co KG Reinhold-Wurth-Str. 12-17 74653 Kunzelsau-Gaisbach Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de |
| 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 | Cleaning spray, Loctite 7063 (150 ml) | A 001 986 71 71 10 |