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

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ENGINES 275 in MODEL 215, 216, 220, 221 

Fig 1: Identifying Crankshaft Remove/Install Components
G10108164Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

28.5.08 Clean sealing surfaces - added Step 19  
REMOVING 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) IMPORTANT Loosen bolts (7, 8, 9) in reverse order of tightening procedure:
↓		  
Tightening procedure for crankcase bottom section
IMPORTANT Observe dowel pins when prying off. If lower crankcase section (1) cannot be pryed off: ↓
Remove dowel pins		 AR03.20-P-4351-05L
SPECIAL TOOL Figure
SPECIAL TOOL Figure
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 IMPORTANT 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 IMPORTANT Do not mix up top and bottom connecting rod bearing shells.  
15 Mark connecting rod bearing shell and connecting rod to each other IMPORTANT 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)    
INSTALLING Install     
18 Insert crankshaft (2) IMPORTANT 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.
IMPORTANT Observe crankshaft bearing shell assignment:↓		  
Assign crankshaft bearing shells. AR03.20-P-4360-01L
CLEAN Clean     
19 Clean sealing surfaces on lower crankcase section (1) and upper crankcase section (3) NOTES 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) IMPORTANT Lubricate bolts for the lower crankcase section (1) on thread and bolt head contact surface.
IMPORTANT Observe sealant flow and tightening procedure:↓		  
IMPORTANT Notes on application of sealant to crankcase bottom section AH01.40-P-1000-03A
SPECIAL TOOL Figure
Loctite 5970 sealant *BR00.45-Z-1013-01A 
Tightening procedure for crankcase bottom section AR03.20-P-4351-05L
TORQUE SPECIFICATION *BA01.40-P-1008-01C 
21 Crank crankshaft (2) IMPORTANT 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 IMPORTANT The anti-twist locks of connecting rod bearing shells must be located in slots of connecting rods and of connecting rod bearing caps.
IMPORTANT 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
TORQUE SPECIFICATION *BA03.10-P-1001-01E 
26 Crank crankshaft (2) IMPORTANT to check for unobstructed movement.  
27 Install oil pump   AR18.10-P-6020L
28 Install oil deflector plate TORQUE SPECIFICATION *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 IMPORTANT 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 IMPORTANT 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 ∠° - -
    -   - -
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)
G07742707Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Impact Extractor (116 589 20 33 00)
G07742706Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Squeeze Gun (112 589 00 25 00)
G07742715Courtesy 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 Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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