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

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ENGINES 273 in MODEL 216, 221

Fig 1: Identifying Crankshaft Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Crankshaft Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

26.11.07	Installation note on install new chain tensioner, added	Step 42
18.2.08	Special tool (136 589 04 21 00) removed and replaced by special tool (363 589 02 21 00)		AR03.20-P-4291-03SX

	Removing
1	Drain engine oil
	Engine oil and filter change		AP18.00-P-0101SX
2	Remove engine with front axle carrier	Vehicles without 4MATIC	AR01.10-P-2500SX
2	Remove engine with front axle carrier	Vehicles with 4MATIC	AR01.10-P-2500SW
3	Detach engine from front axle carrier	Vehicles without 4MATIC	AR01.10-P-2510SX
3	Detach engine from front axle carrier	Vehicles with 4MATIC	AR01.10-P-2510TW
4	Remove automatic transmission from engine	Vehicles without 4MATIC	AR27.10-P-0500SX
4	Remove automatic transmission from engine	Vehicles with 4MATIC	AR27.10-P-0500SYZ
5	Mount engine onto assembly stand
6	Remove front cover at left cylinder head		AR01.30-P-5700SX
7	Remove the right cylinder head cover		AR01.20-P-5014SY
8	Rotate engine at crankshaft (7) in direction of rotation of engine to a 40° crank angle after ignition TDC and check basic position of camshaft		AR05.20-P-6010-01VB
9	Remove driven plate		AR03.30-P-8001SX
10	Remove oil pan bottom section	Vehicles without 4MATIC	AR01.45-P-7555SX
10	Remove oil pan bottom section	Vehicles with 4MATIC	AR01.45-P-7555SW
11	Detach oil pan	Vehicles without 4MATIC	AR01.45-P-7500SX
11	Detach oil pan	Vehicles with 4MATIC	AR01.45-P-7500SW
12	Remove rear crankshaft radial sealing ring		AR03.20-P-3063SX
13	Remove oil pump		AR18.10-P-6020SX
14	Remove oil baffle from cylinder crankcase		AR03.10-P-7021-01SX
15	Remove alternator		AR15.40-P-5032SX
16	Remove chain tensioner		AR05.10-P-7800SX
17	Remove timing case cover	Do not damage cylinder head gaskets.	AR01.40-P-8000SX
18	Remove oil pump chain (12)
19	Remove camshaft adjuster (13) on right cylinder head		AR05.20-P-7201SX
20	Detach timing chain drive gear (14) from crankshaft (7)	Secure key (15).
21	Mark connecting rods (1) and connecting rod bearing caps (2) on one side relative to each other	Connecting rod (1) and connecting rod bearing cap (2) are cracked. They must not be swapped or installed on wrong sides as the dimensional accuracy would no longer be given.
22	Remove connecting rod bearing cap (2) and lower connecting rod bearing shells (3)	Mark connecting rod bearing cap (2) and lower connecting rod bearing shells (3) relative to each other. Mark connecting rods (1) and connecting rod bearing caps (4) relative to each other. While rotating crankshaft (7) ensure that connecting rods (1) do not get caught.
23	Loosen crankshaft bearing cap (5) bolts and crankshaft fitted bearing cap (6) in reverse order of tightening procedure		AR03.20-P-4351-02SX
24	Remove crankshaft bearing cap (5) and crankshaft fitted bearing cap (6)	Carefully pry out crankshaft bearing cap (5) and crankshaft fitted bearing cap (6). Mark the lower crankshaft bearing shells (9) relative to their respective crankshaft bearing caps (5) and crankshaft fitted bearing caps (6). Mark lower thrust plates (11) relative to crankshaft fitted bearing cap (6).
25	Remove crankshaft (7) from crankcase
26	Remove upper crankshaft bearing shells (8) and upper thrust washers (10) from crankcase	Mark upper crankshaft bearing shells (8) and upper thrust washers (10) from crankcase relative to crankshaft fitted bearing.
	Install
27	Lubricate upper crankshaft bearing shells (8) and insert them into crankcase	When replacing the crankshaft bearing shells (8, 9) or the crankshaft (7): ↓
		Assign crankshaft bearing shells.	AR03.20-P-4360-01SX
		Main bearing play	*BE03.20-P-1001-04E
28	Lubricate crankshaft journals and insert crankshaft (7) in crankcase
29	Lubricate upper thrust plate (10) and insert in crankshaft fitted bearing in crankcase	Oil grooves in the upper thrust plates (10) must point toward the thrust collars of the crankshaft (7).
30	Lubricate lower crankshaft bearing shells (9) and lower thrust plates (11) and insert in crankshaft bearing cap (5) and crankshaft fitted bearing cap (6)	When replacing the crankshaft bearing shells (8, 9) or the crankshaft (7): ↓
		Assign crankshaft bearing shells.	AR03.20-P-4360-01SX
		Main bearing play	*BE03.20-P-1001-04E
31	Insert crankshaft bearing cap (5) and crankshaft fitted bearing cap (6)	The crankshaft bearing caps (5) and fitted bearing caps (6) are numbered consecutively. Pay attention to fit: ↓
		Fit of crankshaft bearing cap	AH03.20-P-4351-02SX
32	Insert and tighten bolts for crankshaft bearing caps (5) and for crankshaft fitted bearing cap (6)	Bolts must be replaced with new ones, otherwise there is risk of breakage. Tighten bolts according to tightening scheme: ↓
		Tightening procedure for crankshaft bearing caps	AR03.20-P-4351-02SX
			*BA03.20-P-1001-01D
			*BA03.20-P-1002-01D
			*BA03.20-P-1003-01D
33	Rotate crankshaft (7) and check for unobstructed movement
34	Determine crankshaft bearing axial play		AR03.20-P-4291-03SX
			Figure
			Fig 4
			Figure
		Main bearing play	*BE03.20-P-1001-04E
35	Check connecting rod bolts		AR03.10-P-6111-01VA
35	Check connecting rod bolts	Connecting rod bolts	*BE03.10-P-1001-03A
36	Mount connecting rod bearing	Connecting rod (1) and connecting rod bearing cap (2) are cracked. They must not be swapped or installed on wrong sides as the dimensional accuracy would no longer be given.	AR03.10-P-6111-08SX
		Connecting rod bearing play	*BE03.20-P-1002-04E
			*BA03.10-P-1001-01E
37	Rotate crankshaft (7) and check for unobstructed movement
38	Slide timing chain drive gear (14) onto crankshaft (7)	Observe key (15).
39	Install camshaft adjuster (13) on right cylinder head while adjusting basic positions of camshaft	Check engine timing at a 40° crank angle after ignition TDC. At 40° crank angle after ignition TDC, fitting key (15) aligns with the marking (16) on the cylinder crankcase.	AR05.20-P-7201SX
40	lay oil pump chain (12) on drive gear
41	Install timing case cover		AR01.40-P-8000SX
42	Install chain tensioner	Replace chain tensioner. The previously installed chain tensioner must not be reinstalled because, during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.	AR05.10-P-7800SX
43	Mount oil baffle on cylinder crankcase		AR03.10-P-7021-01SX
43	Mount oil baffle on cylinder crankcase		*BA18.10-P-1006-01B
44	Install oil pump		AR18.10-P-6020SX
45	Installing rear crankshaft radial sealing ring	Replace rear crankshaft radial sealing ring with new one to ensure that there are no leaks.	AR03.20-P-3063SX
46	Install oil pan	Vehicles without 4MATIC	AR01.45-P-7500SX
46	Install oil pan	Vehicles with 4MATIC	AR01.45-P-7500SW
47	Install oil pan bottom section	Vehicles without 4MATIC	AR01.45-P-7555SX
47	Install oil pan bottom section	Vehicles with 4MATIC	AR01.45-P-7555SW
48	Install alternator		AR15.40-P-5032SX
49	Fit right cylinder head cover		AR01.20-P-5014SY
50	Install front cover on left cylinder head		AR01.30-P-5700SX
51	Install drive plate		AR03.30-P-8001SX
52	Mount automatic transmission to engine	Vehicles without 4MATIC	AR27.10-P-0500SX
52	Mount automatic transmission to engine	Vehicles with 4MATIC	AR27.10-P-0500SYZ
53	Install engine onto front axle carrier	Vehicles without 4MATIC	AR01.10-P-2510SX
53	Install engine onto front axle carrier	Vehicles with 4MATIC	AR01.10-P-2510TW
54	Install engine with front axle carrier	Vehicles without 4MATIC	AR01.10-P-2500SX
54	Install engine with front axle carrier	Vehicles with 4MATIC	AR01.10-P-2500SW
55	Pour in engine oil
	Engine oil and filter change		AP18.00-P-0101SX

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 273
BE03.20-P-1001-04E	Main bearing play	Radial measurement new	mm	0.022...0.046
BE03.20-P-1001-04E	Main bearing play	Axial measurement when new	mm	0.100 to 0.266
BE03.20-P-1002-04E	Connecting rod bearing play	Radial measurement new	mm	0.022...0.066

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number	Designation				Engine 273
BE03.10-P-1001-03A	Connecting rod bolts	Thread dia.		M	8X1
		Shank length	New	mm	39.5
			max.	mm	40.5

CRANKSHAFT BEARING CAP

Number	Designation				Engine 273
BA03.20-P-1001-01D	Bolt for crankshaft bearing cap	M8	Stage 1	Nm	20
BA03.20-P-1001-01D	Bolt for crankshaft bearing cap	M8	Stage 2	∠°	90
BA03.20-P-1002-01D	Side crankshaft bearing cap bolt	M8	Stage 1	Nm	20
BA03.20-P-1002-01D	Side crankshaft bearing cap bolt	M8	Stage 2	∠°	90
BA03.20-P-1003-01D	Bolt for crankshaft bearing cap	M10	Stage 1	Nm	5
			Stage 2	Nm	30
			Stage 3	∠°	90

CONNECTING ROD

Number	Designation			Engine 273
BA03.10-P-1001-01E	Connecting rod bolt	Stage 1	Nm	5
		Stage 2	Nm	25
		Stage 3	∠°	90

OIL PUMP

Number	Designation		Engine 273
BA18.10-P-1006-01B	Bolt, oil baffle to crankcase	Nm	9

Fig 3: Identifying Dial Indicator (001 589 32 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Extension (366 589 00 21 05)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Dial Indicator Holder (363 589 02 21 00)

Courtesy of MERCEDES-BENZ USA