Remove/install crankshaft - AR03.20-P-4351MC

ENGINES 275 in MODEL 215, 216, 220, 221 

Fig 1: Identifying Crankshaft Components

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

28.5.08

Clean sealing surfaces - added

Step 19

	Removing
1.1	Remove engine	Model 215, 220 except 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07 Model 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07	AR01.10-P-2400MC
1.2	Remove engine with front axle carrier	Model 216, 221	AR01.10-P-2500SZ
2	Remove transmission	Model 216, 221	AR27.10-P-0500SZ
3	Detach engine from front axle carrier	Model 216, 221	AR01.10-P-2510SX
4	Mount engine onto assembly stand
5	Remove end cover		AR01.40-P-8913MC
6	Remove timing case cover		AR01.40-P-8000M
7	Remove oil pan	Model 215, 220	AR01.45-P-7500L
		Model 216, 221	AR01.45-P-7500SZ
8	Remove oil deflector plate
9	Remove oil pump		AR18.10-P-6020L
10	Remove bolts (M10) (7), bolts (M8) (8), bolts (M6) (9) and prise off crankcase bottom section (1)	Loosen bolts (7, 8, 9) in reverse order of tightening procedure: ↓
		Tightening procedure for crankcase bottom section Observe dowel pins when prying off. If lower crankcase section (1) cannot be pryed off: ↓ Remove dowel pins	AR03.20-P-4351-05L
			*116589013400
			*116589203300
11	Place match marks on crankshaft bearing shells in lower crankcase section (without oil hole) (6) and on crankshaft bearings in lower crankcase section (1)
12	Place match marks on connecting rod and connecting rod bearing cap
13	Remove connecting rod bearing caps	While turning crankshaft (2) ensure that connecting rods do not get jammed.
14	Mark connecting rod bearing shell and connecting rod bearing cap to each other	Do not mix up top and bottom connecting rod bearing shells.
15	Mark connecting rod bearing shell and connecting rod to each other	Do not mix up top and bottom connecting rod bearing shells.
16	Take crankshaft (2) out of crankcase top section (3)
17	Place match marks on crankshaft bearing shells in upper crankcase section (with oil hole) (4) and on crankshaft bearings in upper crankcase section (3)
	Install
18	Insert crankshaft (2)	Lubricate crankshaft bearing shells in upper crankcase section (with oil hole) (4) before installing crankshaft (2). The oil grooves in the thrust washers (thrust bearing) (5/1) and thrust washers (thrust bearing) (5/2) must point towards thrust collars of the crankshaft (2). Thrust washers (thrust bearing) (5/1) and thrust washers (thrust bearing) (5/2) are each fitted with a retaining lug as an anti-twist lock. Observe crankshaft bearing shell assignment: ↓
		Assign crankshaft bearing shells.	AR03.20-P-4360-01L
	Clean
19	Clean sealing surfaces on lower crankcase section (1) and upper crankcase section (3)	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.	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 lower crankcase section (1)	Lubricate bolts for the lower crankcase section (1) on thread and bolt head contact surface. Observe sealant flow and tightening procedure: ↓
		Notes on application of sealant to crankcase bottom section	AH01.40-P-1000-03A
			*112589002500
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
		Tightening procedure for crankcase bottom section	AR03.20-P-4351-05L
			*BA01.40-P-1008-01C
21	Crank crankshaft (2)	To check for unobstructed movement.
22	Check axial play of crankshaft (2)		AR03.20-P-4355-02L
23	Check connecting rod bolts		AR03.10-P-6111-01L
24	Fit connecting rod bearing and mount connecting rod bearing cap	The anti-twist locks of connecting rod bearing shells must be located in slots of connecting rods and of connecting rod bearing caps. The connecting rod and connecting rod bearing cap are broken. They must not be installed on wrong side since the accuracy of fit would no longer be given.	AR03.10-P-6111-06L
25	Tighten connecting rod bolts		AR03.10-P-6111-02L
			*BA03.10-P-1001-01E
26	Crank crankshaft (2)	to check for unobstructed movement.
27	Install oil pump		AR18.10-P-6020L
28	Install oil deflector plate		*BA01.40-P-1009-01C
29	Installing oil pan	Model 215, 220	AR01.45-P-7500L
		Model 216, 221	AR01.45-P-7500SZ
30	Install timing case cover	Replace the O-rings and radial sealing ring. The sealing lip of radial sealing ring and its mating surface must not be oiled or greased. Pay attention to fitted sleeves when pressing on end cover!	AR01.40-P-8000M
31	Install end cover	Replace radial sealing ring. The sealing lip of radial sealing ring and its mating surface must not be oiled or greased. Pay attention to the fitted sleeves when pressing on the end cover.	AR01.40-P-8913MC
32	Detach engine from engine assembly stand
33	Install engine onto front axle carrier	Model 216, 221	AR01.10-P-2510SX
34	Attach transmission	Model 216, 221	AR27.10-P-0500SZ
35.1	Install engine	Model 215, 220 except 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07 Model 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07	AR01.10-P-2400MC
35.2	Install engine with front axle carrier	Model 216, 221	AR01.10-P-2500SZ

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation					Engine 137	Engine 275, 285
BA01.40-P-1008-01C	Bolt, crankcase bottom section to top part	1-14	M10	Stage 1	Nm	40	40
				Stage 2	∠°	90	90
		15-28	M8	Stage 1	Nm	12	12
				Stage 2	∠°	90	90
				Stage 3	∠°	90	90
		29-54	M6	Stage 1	Nm	8	8
				Stage 2	∠°	-	-
		55-61	M8	Stage 1	Nm	20	20
				Stage 2	∠°	-	-
				See picture		-	-
BA01.40-P-1009-01C	Bolt, oil baffle to lower crankcase section				Nm	8	8

CONNECTING ROD

Number	Designation			Engine 275, 285
BA03.10-P-1001-01E	Connecting rod bolt	Stage 1	Nm	5
		Stage 2	Nm	15
		Stage 3	∠°	90

Fig 2: Identifying Threaded Stud (116 589 01 34 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA

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
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10