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

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ENGINES 272 in MODEL 221 

Fig 1: Identifying Crankshaft Remove/Install Components - Shown Without Pulse Wheels On Camshaft Adjusters
G10126332Courtesy of MERCEDES-BENZ USA

Shown without pulse wheels on camshaft adjusters 

Fig 2: Identifying Crankshaft Remove/Install Components
G10126333Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

10.2.10 Value modified: Side crankshaft bearing cap bolt, Stage 1   *BA03.20-P-1002-01D 
  Value modified: Side crankshaft bearing cap bolt, Stage 2   *BA03.20-P-1002-01D 
REMOVING Removing     
1 Drain engine oil    
REFER TO MAINTENANCE Engine oil and filter change   AP18.00-P-0101SX
2 Remove engine with front axle carrier Vehicles without 4MATIC AR01.10-P-2500SX
Vehicles with 4MATIC AR01.10-P-2500SW
3 Detach engine from front axle carrier Vehicles without 4MATIC AR01.10-P-2510SX
Vehicles with 4MATIC AR01.10-P-2510TW
4 Remove automatic transmission from engine Vehicles without 4MATIC AR27.10-P-0500SX
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 right cylinder head cover (12)   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
9.1 Remove driven plate Except model 221.095/195 AR03.30-P-8001SX 
9.2 Remove integrated starter alternator Model 221.095/195 AR15.40-P-0003SXH
10 Remove oil pan bottom section Vehicles without 4MATIC AR01.45-P-7555SX
Vehicles with 4MATIC AR01.45-P-7555SW
11 Detach oil pan Vehicles without 4MATIC AR01.45-P-7500SY
Vehicles with 4MATIC AR01.45-P-7500SW
12 Remove rear crankshaft radial sealing ring Except model 221.095/195 AR03.20-P-3063SX 
Model 221.095/195 AR03.20-P-3063SXH 
13 Remove oil pump   AR18.10-P-6020SX
14 Remove oil baffle from cylinder crankcase   AR03.10-P-7021-01SX
15 Remove alternator Except model 221.095/195 AR15.40-P-5032SX
Model 221.095/195 AR15.40-P-5032SXH
16 Remove chain tensioner   AR05.10-P-7800SX
17 Remove timing case cover NOTES Do not damage cylinder head gaskets. AR01.40-P-8000SX
18 Remove oil pump chain (11)    
19 Remove camshaft adjuster (13) on right cylinder head Intake camshaft AR05.20-P-7201SX
Exhaust camshaft AR05.20-P-7201SY
20 Detach timing chain drive gear (14) from crankshaft (7) IMPORTANT Secure key (15).  
21 Mark connecting rod (1) and connecting rod bearing cap (2) on one side relative to each other (arrow) IMPORTANT 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) IMPORTANT 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-4351-02VA
24 Remove crankshaft bearing cap (5) and crankshaft fitted bearing cap (6) IMPORTANT Carefully pry out crankshaft bearing cap (5) and crankshaft fitted bearing cap (6). Mark lower crankshaft bearing shells (10) relative to the respective crankshaft bearing caps (5) and crankshaft fitted bearing caps (6). Mark lower thrust plate (9) relative to crankshaft fitted bearing cap (6).  
25 Remove crankshaft (7) from crankcase    
26 Take out upper crankshaft bearing shells (8) and upper thrust plates (9) from the crankcase IMPORTANT Mark upper crankshaft bearing shell (8) relative to respective crankshaft bearing and upper thrust plate (9) relative to crankshaft fitted bearing.  
INSTALLING Install     
27 Lubricate upper crankshaft bearing shells (8) and insert them into crankcase IMPORTANT When replacing crankshaft bearing shells (8, 10) or crankshaft (7): ↓  
Assign crankshaft bearing shells. AR03.20-P-4360-01VA
Main bearing play *BE03.20-P-1001-04E 
28 Lubricate crankshaft journals and insert crankshaft (7) in crankcase IMPORTANT Lubricate crankshaft journals.  
29 Lubricate upper thrust plates (9) without retaining lugs and insert them into crankshaft fitted bearing in crankcase IMPORTANT Oil grooves in upper thrust plates (9) must point toward thrust collars of crankshaft (7).  
30 Lubricate lower crankshaft bearing shells (10) and lower thrust plates (9) with retaining lugs and insert them into crankshaft bearing cap (5) and into crankshaft fitted bearing cap (6) IMPORTANT When replacing crankshaft bearing shells (8, 10) or crankshaft (7): ↓  
Assign crankshaft bearing shells. AR03.20-P-4360-01VA
Main bearing play *BE03.20-P-1001-04E 
31 Insert crankshaft bearing cap (5) and crankshaft fitted bearing cap (6) IMPORTANT The crankshaft bearing cap (5) and fitted bearing cap (6) are numbered consecutively. Pay attention to fit:
↓		  
IMPORTANT   Fit of crankshaft bearing cap AH03.20-P-4351-02VA
32 Insert and tighten bolts for crankshaft bearing caps (5) and for crankshaft fitted bearing cap (6) NOTES 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-4351-02VA
TORQUE SPECIFICATION *BA03.20-P-1001-01D 
TORQUE SPECIFICATION *BA03.20-P-1002-01D 
TORQUE SPECIFICATION *BA03.20-P-1003-01D 
33 Rotate crankshaft (7) and check for unobstructed movement    
34 Determine crankshaft bearing axial play   AR03.20-P-4291-03VA
SPECIAL TOOL Figure
SPECIAL TOOL Figure
SPECIAL TOOL Figure
Main bearing play *BE03.20-P-1001-04E 
35 Check connecting rod bolts   AR03.10-P-6111-01VA
Connecting rod bolts *BE03.10-P-1001-03A 
36 Mount connecting rod bearing and check play   AR03.10-P-6111-06VA
Connecting rod bearing play *BE03.20-P-1002-04E 
37 Tighten connecting rod bolts   AR03.10-P-6111-02VA
TORQUE SPECIFICATION *BA03.10-P-1001-01E 
38 Rotate crankshaft (7) and check for unobstructed movement    
39 Slide timing chain drive gear (14) onto crankshaft (7) IMPORTANT Observe key (15).  
40 Install camshaft adjusters (13) for right cylinder head while setting basic positions of camshafts and balance shaft (16) IMPORTANT Check the engine timing and basic position of balance shaft (16) at 40° crank angle after ignition TDC. At 40° crank angle after ignition TDC, the key (15) aligns with marking (17) on the cylinder crankcase and notch (18) on balance shaft (16) aligns with marking (19).  
Intake camshaft AR05.20-P-7201SX
Exhaust camshaft AR05.20-P-7201SY
41 Place oil pump chain (11) on drive gear    
42 Install timing case cover   AR01.40-P-8000SX
43 Install chain tensioner IMPORTANTReplace 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
44 Mount oil baffle on cylinder crankcase   AR03.10-P-7021-01SX
TORQUE SPECIFICATION *BA18.10-P-1006-01B 
45 Install oil pump   AR18.10-P-6020SX
46 Installing rear crankshaft radial sealing ring NOTES Replace rear crankshaft radial sealing ring with new one to ensure that there are no leaks.  
Except model 221.095/195 AR03.20-P-3063SX 
Model 221.095/195 AR03.20-P-3063SXH 
47 Install oil pan Vehicles without 4MATIC AR01.45-P-7500SY
Vehicles with 4MATIC AR01.45-P-7500SW
48 Install oil pan bottom section Vehicles without 4MATIC AR01.45-P-7555SX
Vehicles with 4MATIC AR01.45-P-7555SW
49 Install alternator Except model 221.095/195 AR15.40-P-5032SX
Model 221.095/195 AR15.40-P-5032SXH
50 Install right cylinder head cover (12)   AR01.20-P-5014SY
51 Install front cover on left cylinder head   AR01.30-P-5700SX
52.1 Install drive plate Except model 221.095/195 AR03.30-P-8001SX 
52.2 Install integrated starter alternator Model 221.095/195 AR15.40-P-0003SXH
53 Mount automatic transmission to engine Vehicles without 4MATIC AR27.10-P-0500SX
Vehicles with 4MATIC AR27.10-P-0500SYZ
54 Install engine onto front axle carrier Vehicles without 4MATIC AR01.10-P-2510SX
Vehicles with 4MATIC AR01.10-P-2510TW
55 Install engine with front axle carrier Vehicles without 4MATIC AR01.10-P-2500SX
Vehicles with 4MATIC AR01.10-P-2500SW
56 Pour in engine oil    
REFER TO MAINTENANCE Engine oil and filter change   AP18.00-P-0101SX
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 272
BE03.20-P-1001-04E Main bearing play Radial measurement new mm 0.022...0.046
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 272
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 272
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8 Stage 1 Nm 20
Stage 2 ∠° 90
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Stage 1 Nm 20
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 272
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 20
Stage 3 ∠° 90
OIL PUMP

Number Designation Engine 272
BA18.10-P-1006-01B Bolt, oil baffle to crankcase Nm 9
Fig 3: Identifying Dial Indicator (001 589 32 21 00)
G10126334Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Extension (366 589 00 21 05)
G10115143Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Dial Indicator Holder (363 589 02 21 00)
G09635463Courtesy of MERCEDES-BENZ USA
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