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

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ENGINE 157, 278 IN MODEL 216, 221, 222, 231 

MODIFICATION NOTES

29.7.14 Document verification validity limited. Workstep validity created. Operation steps 2, 35  
Fig 1: Identifying Crankshaft Remove/Install Components
G10108168Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1 Remove engine with front axle carrier Model 222 with engine 157, 278 AR01.10-P-2500LFB
Model 231 with engine 157, 278 AR01.10-P-2500RKB
Model 216, 221 with engine 157, 278 AR01.10-P-2500MMB
2 Detach transmission with torque converter Engine 157, 278 in model 216, 221, 222, 231  
Model 231 with engine 157 with transmission 722.93
Model 231 with engine 278 with transmission 722.9		 AR27.10-P-0500RK
Model 222 with engine 278 with transmission 722.96 AR27.10-P-0500LHX
Model 222 with engine 157 with transmission 722.931
Model 222 with engine 278 with transmission 722.909		 AR27.10-P-0500LF
Model 216, 221 with engine 157 with transmission 722.9
with 4MATIC Model 216, 221 with engine 278 with transmission 722.9 with 4MATIC		 AR27.10-P-0500SYZ
Model 216.3, 221.0/1 with engine 157 with transmission 722.9
without 4MATIC Model 216.3, 221.0/1 with engine 278 with transmission 722.9 without 4MATIC		 AR27.10-P-0500SX
3 Secure engine to assembly stand    
4 Remove oil pan Model 231 with engine 157, 278 AR01.45-P-7500RKB
Model 222 with engine 157, 278 AR01.45-P-7500LFB
Model 216, 221 with engine 157, 278 AR01.45-P-7500MMB
5 Remove oil pump Model 231 with engine 157, 278 AR18.10-P-6020RKB
Model 222 with engine 157, 278 AR18.10-P-6020LFB
Model 216 with engine 157, 278
Model 221 with engine 157, 278		 AR18.10-P-6020MM
6 Remove rear radial shaft sealing ring Model 231 with engine 157, 278 AR03.20-P-3063RK
Model 222 with engine 157, 278 AR03.20-P-3063LFB
Model 216 with engine 157, 278
Model 221 with engine 157, 278		 AR03.20-P-3063MM 
7 Remove timing case cover Model 231 with engine 157, 278 AR01.40-P-8000RKB
Model 222 with engine 157, 278 AR01.40-P-8000LFB
Model 216, 221 with engine 157, 278 AR01.40-P-8000MMB
IMPORTANT Remove crankshaft radial sealing ring on timing case cover.  
8 Remove timing chain on primary chain drive Model 231 with engine 157, 278 AR05.10-P-7612RKB
Model 222 with engine 157, 278 AR05.10-P-7612LFB
Model 216, 221 with engine 157, 278 AR05.10-P-7612MMB
9 Detach timing chain drive gear (3) from crankshaft (6)    
10 Mark connecting rod and connecting rod bearing cap on one side relative to each other and to the respective cylinder    
11 Remove connecting rod bearing shells and mark relative to the associated connecting rods and connecting rod bearing caps    
12 Loosen crankshaft bearing cap (1) bolts and crankshaft fitted bearing cap (2) in reverse order of tightening procedure Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MM
13 Remove crankshaft bearing cap (1) and crankshaft fitted bearing cap (2) IMPORTANT Carefully lever out crankshaft bearing cap (1) and crankshaft fitted bearing cap (2). Mark the lower crankshaft bearing shells (4) relative to their respective crankshaft bearing caps (1) and crankshaft fitted bearing caps (2).
Mark lower thrust plates (A) relative to the crankshaft fitted bearing cap (2).		  
14 Remove crankshaft (6) from cylinder crankcase    
15 Take out upper crankshaft bearing shells (5) and upper thrust plates (B) from the cylinder crankcase IMPORTANT Mark upper crankshaft bearing shells (5) relative to the respective crankshaft bearing and upper thrust plates (B) relative to the crankshaft fitted bearing.  
CLEAN Clean     
16 Clean all power unit components NOTES
The power unit components must be absolutely free of soiling.
Engine damage may occur otherwise.		  
Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
17 Check all power unit components If damaged or worn
↓
Replace the respective engine section.		  
INSTALLING Install     
18 Insert crankshaft bearing cap (4, 5) in the crankcase.    
  AR03.20-P-4360-01MM
IMPORTANT Observe previously attached note marking.  
19 Insert crankshaft (6) into crankcase and install crankshaft bearing cap (1) and crankshaft fitted bearing cap (2)   AR03.20-P-4360-01MM
20 Insert and tighten screw/bolts for crankshaft bearing caps (1) and for crankshaft fitted bearing cap (2) Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MM
IMPORTANT Observe tightening procedure! Screw/bolts must be replaced.  
TORQUE SPECIFICATION Bolt, crankshaft bearing cap *BA03.20-P-1003-01D 
TORQUE SPECIFICATION Side crankshaft bearing cap bolt *BA03.20-P-1002-01D 
TORQUE SPECIFICATION Bolt for crankshaft bearing cap *BA03.20-P-1001-01D 
21 Rotate crankshaft (6) and check for unobstructed movement    
22 Determine crankshaft bearing axial play   AR03.20-P-4291-03MM
Main bearing play *BE03.20-P-1001-04E 
SPECIAL TOOL Dial indicator holder Fig 3
SPECIAL TOOL Dial gauge Fig 4
23 Check connecting rod bolts   AR03.10-P-6111-01MM
Connecting rod bolts *BE03.10-P-1001-03A 
24 Mount connecting rod bearing   AR03.10-P-6111-06MM
25 Tighten connecting rod bolts   AR03.10-P-6111-02MM
TORQUE SPECIFICATION Connecting rod bolt *BA03.10-P-1001-01E 
26 Rotate crankshaft (6) and check for unobstructed movement    
27 Slide timing chain drive gear (3) onto crankshaft (6) IMPORTANT Ensure correct seating of the fitted spring.  
28 Install timing chain for primary chain drive Model 231 with engine 157, 278 AR05.10-P-7612RKB
Model 222 with engine 157, 278 AR05.10-P-7612LFB
Model 216, 221 with engine 157, 278 AR05.10-P-7612MMB
29 Install timing case cover Model 231 with engine 157, 278 AR01.40-P-8000RKB
Model 222 with engine 157, 278 AR01.40-P-8000LFB
Model 216, 221 with engine 157, 278 AR01.40-P-8000MMB
30 Install new front radial shaft sealing ring   AR03.20-P-3000-01MM
SPECIAL TOOL Sleeve Fig 5
31 Install new rear radial shaft sealing ring   AR03.20-P-3063-01MMB
Loctite 7200 *BR00.45-Z-1038-04A 
Assembly cleaner *BR00.45-Z-1028-04A 
Loctite 5970 sealant *BR00.45-Z-1013-01A 
TORQUE SPECIFICATION Bolt, rear end cover to crankcase *BA01.40-P-1002-01K 
TORQUE SPECIFICATION Screw/bolt, oil pan to crankcase/timing case cover/rear end cover *BA01.45-P-1001-01E 
SPECIAL TOOL Insertion tool Figure
32 Install oil pump Model 231 with engine 157, 278 AR18.10-P-6020RKB
Model 222 with engine 157, 278 AR18.10-P-6020LFB
Model 216 with engine 157, 278 AR18.10-P-6020MM
Model 221 with engine 157, 278  
33 Install oil pan Model 231 with engine 157, 278 AR01.45-P-7500RKB
Model 222 with engine 157, 278 AR01.45-P-7500LFB
Model 216, 221 with engine 157, 278 AR01.45-P-7500MMB
34 Detach engine from assembly stand    
35 Attach transmission with torque converter Engine 157, 278 in model 216, 221, 222, 231  
Model 231 with engine 157 with transmission 722.93
Model 231 with engine 278 with transmission 722.9		 AR27.10-P-0500RK
Model 222 with engine 278 with transmission 722.96 AR27.10-P-0500LHX
Model 222 with engine 157 with transmission 722.931
Model 222 with engine 278 with transmission 722.909		 AR27.10-P-0500LF
Model 216, 221 with engine 157 with transmission 722.9
with 4MATIC Model 216, 221 with engine 278
with transmission 722.9 with 4MATIC		 AR27.10-P-0500SYZ
Model 216.3, 221.0/1 with engine 157 with transmission 722.9
without 4MATIC Model 216.3, 221.0/1 with engine 278 with transmission 722.9 without 4MATIC		 AR27.10-P-0500SX
36 Install engine with front axle carrier Model 222 with engine 157, 278 AR01.10-P-2500LFB
Model 231 with engine 157, 278 AR01.10-P-2500RKB
Model 216, 221 with engine 157, 278 AR01.10-P-2500MMB
CHECK VALUES FOR CONNECTING ROD BOLTS

Number Designation Engine 157, 278
BE03.10-P-1001-03A Connecting rod bolts Thread diameter M 8X1
Shank length When new mm 42, 5
max. mm 43, 3
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 157 Engine 278
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 046 0, 022...0, 046
Axial measurement when new mm 0, 140...0, 280 0, 140...0, 280
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 157 Engine 278
BA01.40-P-1002-01K Bolt, rear end cover to crankcase Nm 9 9
OIL PAN

Number Designation Engine 157 Engine 278
BA01.45-P-1001-01E Screw/bolt, oil pan to crankcase/timing case cover/rear end cover M6 Nm 9 9
CONNECTING ROD

Number Designation Engine 157 Engine 278
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 25 25
Stage 3 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation Engine 157 Engine 278
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation Engine 157 Engine 278
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation Engine 157 Engine 278
BA03.20-P-1003-01D Bolt, crankshaft bearing cap M10 Stage 1 Nm 5 5
Stage 2 Nm 30 30
Stage 3 ∠° 90 90
Fig 2: Identifying Insertion Tool (273 589 00 43 00)
G10094401Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Dial Indicator Holder (363 589 02 21 00)
G09973578Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Dial Gauge (001 589 32 21 00)
G09973938Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Sleeve (119 589 01 14 00)
G10108102Courtesy 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-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
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