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

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ENGINES 642 in MODEL 164

Fig 1: Identifying Crankshaft Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

9.7.10

Value modified: Bolt, connecting rod bearing cap to connecting rod, See picture

*BA03.10-P-1001-01L

	Remove/install
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	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
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1.1	Remove engine		AR01.10-P-2400GZB
1.2	Remove engine with front axle carrier	Model 164	AR01.10-P-2500GZB
1.2	Remove engine with front axle carrier	Model 251	AR01.10-P-2500RTB
2	Remove transmission with torque converter	Model 164	AR27.10-P-0500GZ
2	Remove transmission with torque converter	Model 251	AR27.10-P-0500RTA
3	Remove cylinder head		AR01.30-P-5800GZC
4	Remove oil pan bottom section		AR01.45-P-7555GZB
5	Remove oil pan	Model 164	AR01.45-P-7500GZB
		Model 251 with 4MATIC	AR01.45-P-7500RTB
		Model 251 without 4MATIC	AR01.45-P-7500RTC
6	Remove oil pump		AR18.10-P-6020GZB
7	Remove chain tensioner		AR05.10-P-7800GZB
8	Remove camshaft sprocket		AR05.20-P-6040OM
9	Take off timing case cover		AR01.40-P-8000GZB
10	Remove connecting rods (12)		*BA03.10-P-1001-01L
11	Remove connecting rod	Installation: The connecting rods (11) are cracked (broken) (magnified section). Dimensional accuracy of connecting rods (11) can no longer be guaranteed after opening, therefore new connecting rods must be fitted. The connecting rods (11) are supplied with assembly bolts, which must be replaced by connecting rods (12) with assembly device. Installation: The anti-twist lock (14) for connecting rod bearing shell (13) must fit into groove (15) for connecting rod (11) and for connecting rod bearing cap (16): ↓,
		Install and gauge connecting rod bearings	AR03.10-P-6111-06TI BE03.10-P-1001-01G BE03.10-P-1002-01G BE03.10-P-1003-01G BE03.10-P-1004-01G BE03.10-P-1005-01G BE03.10-P-1006-01G BE03.10-P-1007-01G BE03.10-P-1008-01G BE03.10-P-1009-01G BE03.10-P-1010-01G *BE03.10-P-1011-01G
			*BA03.10-P-1001-01L
12	Remove pistons		AR03.10-P-7021GZB
13	Unscrew crankshaft bearing caps (4, 10) and fitted bearing (5)	Installation: The crankshaft bearing bolts (M11) (8) and crankshaft bearing bolts on the side (M10) (9) must be replaced otherwise there is a risk of cracks and fracture. Loosen crankshaft bearing bolts (M11) (8) and lateral crankshaft bearing bolts (M10) (9) in the opposite direction to the tightening procedure. Installation: Tighten crankshaft bearing bolts (M11) (8) and lateral crankshaft bearing bolts (M10) (9) synchronously and in accordance with the tightening procedure. ↓,
		Tightening procedure for crankshaft bearing caps	AR03.20-P-4351-02TI
			*BA03.20-P-1001-01E
			*BA03.20-P-1002-01E
14	Remove crankshaft bearing caps (4, 10) and fitted bearing (5)	Carefully lever out crankshaft bearing caps (10) and (5). Before removing, mark crankshaft bearing caps (4, 10) and fitted bearing (5).
15	Take crankshaft (1) out of cylinder crankcase
16	Take crankshaft bearing shells with oil hole and oil groove (2) out of crankcase	Installation: Lubricate crankshaft journal and crankshaft bearing shell with oil hole and oil groove (2)!
17	Remove thrust plates (6) from crankcase	Pay attention to installation position.
18	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
19	Check for leaks with engine running		AS00.00-Z-0005-01A

CHECK VALUES FOR CONNECTING ROD

Number	Designation				Engine 642
BE03.10-P-1001-01G	Dimension	Distance from center of connecting rod bearing bore to connecting rod bush bore (L)		mm	167.97 to 168.03
		Width of connecting rod	Connecting rod bearing bore (B)	mm	18.1 to 18.6
		Width of connecting rod	Connecting rod bush bore (b)	mm	21.94 to 22.0
		See picture			-
BE03.10-P-1002-01G	Dimension	Connecting rod bearing shell basic bore (D1) 0		mm	67.600 to 67.614
		Permissible out-of-roundness and conicity of basic bore		mm	0.007
		See picture			-
BE03.10-P-1003-01G	Dimension	Permissible twist of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm		mm	0.100
BE03.10-P-1004-01G	Dimension	Permissible variation of axial parallelism of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm		mm	0.045
BE03.10-P-1005-01G	Dimension	Permissible weight difference between complete connecting rods in the same engine		g	2
BE03.10-P-1006-01G	Dimension	Connecting rod bush inside Ø (d)		mm	30.038 to 30.044
BE03.10-P-1006-01G	Dimension	See picture			-
BE03.10-P-1007-01G	Dimension	Connecting rod bush outside dia.		mm	-
BE03.10-P-1008-01G	Dimension	Connecting rod bush basic bore Ø(d1)		mm	32.500 to 32.525
BE03.10-P-1008-01G	Dimension	See picture			-
BE03.10-P-1009-01G	Dimension	Piston pin play in connecting rod bushing		mm	0.028 to 0.039
BE03.10-P-1010-01G	Dimension	Peak-to-valley height (R) inside connecting rod bush		μm	5
BE03.10-P-1011-01G	Connecting rod bolt	Thread dia.		M	8.5 X 1
BE03.10-P-1011-01G	Connecting rod bolt	Shank length when new		mm	47 (±0.3)

CRANKSHAFT BEARING CAP

Number	Designation				Engine 642
BA03.20-P-1001-01E	Bolt, crankshaft bearing cap bolt to crankshaft bearing body	M10	Stage 1	Nm	5
			Stage 2	Nm	35
			Stage 3	∠°	95
			Stage 4	∠°	95
BA03.20-P-1002-01E	Lateral bolt connecting crankcase to crankcase bearing cap	M10	Stage 1	Nm	53
BA03.20-P-1002-01E	Lateral bolt connecting crankcase to crankcase bearing cap		Stage 2	∠°	95

CONNECTING ROD

Number	Designation			Engine 642
BA03.10-P-1001-01L	Bolt, connecting rod bearing cap to connecting rod	Stage 1 short arm	Nm	15
		Stage 2 long arm	Nm	20
		Stage 3 short arm	Nm	30
		Stage 4 long arm	Nm	40
		Stage 5 short arm	Nm	40
		Stage 5 short arm	∠°	90
		Stage 6 long arm	∠°	90
		Stage 7 short arm	∠°	90
		Stage 8 long arm	∠°	90
		See picture		AR03.10-P-6111-06TI