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Remove/Install Crankshaft - AR03.20-P-4351MNL

Engine 176 in model 217, 222 

MODIFICATION NOTES

25.04.2018 Document completely revised.    
13.04.2018 Check crankshaft bearing shells, lower thrust plates (7), upper thrust plates (6) and crankshaft bearing journals for wear and damage, added. Operation step 28  
13.04.2018 Check connecting rod bearing shells and connecting rod journals for wear and damage, added. Operation step 29  
22.07.2020 Main bearing play Engine 176 BE03.20-P-1001-04E
G15365755Courtesy of MERCEDES-BENZ USA
G15365756Courtesy of MERCEDES-BENZ USA
WARNING Risk of injury  . Moving parts can pinch, crush or, in extreme cases even sever extremities. No parts of the body or limbs should be within the operating area of mechanical components when moving components. AS00.00-Z-0009-01A
CAUTION Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning 
caused by swallowing engine oil		 Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.		 AS18.00-Z-0001-01A
CAUTION Risk of injury  caused by scraping or cutting Always wear protective gloves when working AS00.00-Z-0017-01A
  body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		  
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
REMOVING Remove     
1 Remove engine from front axle carrier.   AR01.10-P-2510MNL
2 Attach engine to assembly stand.    
REFER TO SPECIAL TOOLS 000 588 00 31 00 Assembly stand for cars   WS01.00-Z-3028KOB
3 Remove engine crane with load tilter from engine.    
REFER TO SPECIAL TOOLS 000 588 00 62 00 Load tilter   WS01.00-P-0102B
    IMPORTANT Commercially available devices/tools
Engine crane		  
4 Remove front engine lifting lug. SPECIAL TOOL Lifting eye Fig 2
5 Remove timing chain on primary chain drive.   AR05.10-P-7613MNL
6 Remove camshafts of left and right cylinder bank. Camshafts of right cylinder bank AR05.20-P-6994MNL
    Camshafts of left cylinder bank AR05.20-P-6993MNL
7 Remove roller-type rocker arms and compensating elements.   AR05.00-P-2011MNL
8 Remove left front engine carrier. Engine 176 in model 217, 222 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-4325MNK
    Engine 176 in model 217, 222 except code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-4325MNL
9 Insert the center bolt for the vibration damper into the crankshaft (1).    
10 Mark installation position on connecting rod bearing caps and connecting rods. NOTES
Do not interchange the connecting rod bearing caps.
Engine damage can occur otherwise.		  
11 Remove connecting rod bolts (3) and remove connecting rod bearing caps. NOTES
The connecting rods and the connecting rod bearing caps are cracked (broken). Do not mix up connecting rods.
Engine damage can occur otherwise.
IMPORTANT When turning crankshaft (1), ensure that connecting rods do not cant.		  
12 Mark connecting rod bearing shells relative to associated connecting rod and connecting rod bearing cap. Only where connecting rod bearing shells are reused.
NOTES
Do not mix up the connecting rod bearing shells.
Engine damage can occur otherwise.		  
13 Remove connecting rod bearing shells.    
14 Determine crankshaft main bearing end play.   AR03.20-P-4291-03MNA 
    HAND-HELD TESTER Main bearing play *BE03.20-P-1001-04E 
    SPECIAL TOOL Mount dial indicator Fig 3
    SPECIAL TOOL Dial indicator holder
If the maximum value of the crankshaft main bearing end play is exceeded:
↓
Replace upper thrust plates (6) and lower thrust plates (7), and perform check again.
If the maximum value of the crankshaft main bearing end play is exceeded again,
↓
Replace crankshaft (1), lower crankshaft bearing shells, upper crankshaft bearing shells, connecting rod bearing shells and crankcase.		 Fig 4
15 Mark crankshaft bearing caps and crankshaft main bearing cap (4) relative to crankcase. NOTES
Crankshaft bearing caps, crankshaft main bearing cap (4) and crankcase are produced together. Do not mix up.
Engine damage can occur otherwise.		  
16 Release screws (2, 5) in reverse order to tightening procedure. Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MNA 
17 Remove crankshaft bearing caps and crankshaft main bearing cap (4).    
18 Mark lower crankshaft bearing shells relative to respective crankshaft bearing caps and crankshaft main bearing cap (4). Only where crankshaft bearing shells are reused.  
19 Mark lower thrust plates (7) relative to crankshaft main bearing cap (4). Only where lower thrust plates (7) are reused.  
20 Remove lower crankshaft bearing shells from crankshaft bearing caps and crankshaft main bearing cap (4).    
21 Remove lower thrust plates (7) from crankshaft main bearing cap (4).    
22 Remove crankshaft (1) from crankcase.    
23 Mark upper crankshaft bearing shells relative to crankcase. Only where upper crankshaft bearing shells are reused.  
24 Mark the upper thrust plates (6) relative to the crankcase. Only where upper thrust plates (6) are reused.  
25 Remove upper crankshaft bearing shells and upper thrust plates (6) from crankcase.    
26 Clean all parts of crank assembly. NOTES
The parts of the crank assembly must be absolutely free of soiling.
Engine damage can occur otherwise.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
  Information on assessing wear of main bearings and main bearing journals   AH03.20-P-1000-02MM 
  Notes on assessing wear on connecting rod bearings and connecting rod journals   AH03.10-P-0001-03MM 
27 Check crankshaft (1) in removed state. Only where crankshaft (1) is reused.  
      AR03.20-P-4463-01MNM 
    IMPORTANTCommercially available devices/tools 
Outside micrometer
Quick calipers for internal measurements		  
    HAND-HELD TESTER Crankshaft journal Ø *BE03.20-P-1001-02J 
    HAND-HELD TESTER Crankshaft bearing *BE01.40-P-1001-04C 
    TORQUE SPECIFICATION Bolt, crankshaft bearing cap to crankcase *BA03.20-P-1002-01N 
    HAND-HELD TESTER Connecting rod bearing journal Ø *BE03.20-P-1003-02J 
    HAND-HELD TESTER Basic bore width at fit bearing *BE01.40-P-1002-04C 
    SPECIAL TOOL Dial gauge Fig 1
28 Check crankshaft bearing shells, lower thrust plates (7), upper thrust plates (6) and crankshaft bearing journals for wear and damage. If problems occur:
↓
Replace crankshaft bearing shells, lower thrust plates (7), upper thrust plates (6) and/or crankshaft (1).		  
29 Check connecting rod bearing shells and connecting rod journals for wear and damage. If problems occur:
↓
Replace connecting rod bearing shells and/or crankshaft (1).		  
INSTALLING Install     
30 Assign new upper crankshaft bearing shells and new lower crankshaft bearing shells. Only when replacing upper crankshaft bearing shells and lower crankshaft bearing shells. AR03.20-P-4360-01MM 
31 Wet upper crankshaft bearing shells and upper thrust plates (6) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
32.1 Insert new upper crankshaft bearing shells and new upper thrust plates (6) into crankcase. Only when replacing upper crankshaft bearing shells and upper thrust plates (6).  
32.2 Insert previously marked upper crankshaft bearing shells and previously marked upper thrust plates (6) at respectively marked location in crankcase. Only where upper crankshaft bearing shells and upper thrust plates (6) are reused.  
33 Wet crankshaft journals with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
34 Position crankshaft (1) in crankcase.    
35 Wet lower crankshaft bearing shells with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
36.1 Insert new lower crankshaft bearing shells into crankshaft bearing caps and into crankshaft main bearing cap (4). Only when replacing lower crankshaft bearing shells.  
36.2 Insert previously marked lower crankshaft bearing shells into respectively marked crankshaft bearing cap and marked crankshaft main bearing cap (4). Only where lower crankshaft bearing shells are reused.  
37 Wet the lower thrust plates (7) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
38.1 Insert new lower thrust plates (7) into crankshaft main bearing cap (4). Only where lower thrust plates (7) are replaced.  
38.2 Insert previously marked lower thrust plates (7) at respectively marked location in crankshaft main bearing cap (4). Only where lower thrust plates (7) are reused.  
39 Install crankshaft bearing caps and crankshaft main bearing cap (4) relative to respectively marked location in crankcase.   AR03.20-P-4360-01MM 
    NOTES Install crankshaft bearing caps and crankshaft main bearing cap (4) at same location and in same direction.
Engine damage can occur otherwise.		  
40 Wet bolt heads of new bolts (2, 5) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
    IMPORTANT Replace screws.  
41 Screw in new bolts (2, 5). Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MNA 
    IMPORTANT Observe tightening procedure.  
    TORQUE SPECIFICATION Bolt, crankshaft bearing cap to crankcase *BA03.20-P-1002-01N 
    TORQUE SPECIFICATION Side bolt to crankshaft bearing cap *BA03.20-P-1001-01N 
42 Turn crankshaft (1) at center bolt of vibration damper and check for unobstructed movement. If the crankshaft (1) is sluggish or jams,
↓
Check correct use and seat of upper crankshaft bearing shells and lower crankshaft bearing shells.		  
      AR03.20-P-4360-01MM 
43 Check connecting rod bolts (3) and replace if necessary.   AR03.10-P-6111-01MNA 
    HAND-HELD TESTER Connecting rod bolts *BE03.10-P-1001-03A 
44 Install connecting rod bearing shells.   AR03.10-P-6111-08MNA 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
45 Tighten connecting rod bolts (3).   AR03.10-P-6111-02MNA 
    TORQUE SPECIFICATION Bolt, connecting rod bearing cap to connecting rod *BA03.10-P-1001-01W 
46 Turn crankshaft (1) at center bolt of vibration damper and check for unobstructed movement. If the crankshaft (1) is sluggish or jams,
↓
Check for correct use and seating of the connecting rod bearing shells.		  
      AR03.10-P-6111-08MNA 
47 Remove center bolt of vibration damper from crankshaft (1).    
48 Install left front engine carrier. Engine 176 in model 217, 222 with code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-4325MNK
    Engine 176 in model 217, 222 except code M005 (Vehicles with 4MATIC/all-wheel drive) AR22.10-P-4325MNL
49 Insert roller-type rocker arms and compensating elements.   AR05.00-P-2011MNL
50 Install camshafts of left and right cylinder bank. Camshafts of right cylinder bank
Camshafts of left cylinder bank		 AR05.20-P-6994MNL
      AR05.20-P-6993MNL
51 Install timing chain for primary chain drive   AR05.10-P-7613MNL
52 Remove front engine lifting lug. SPECIAL TOOL Lifting eye Fig 2
53 Attach engine crane and load tilter to all engine lifting lugs.    
REFER TO SPECIAL TOOLS 000 588 00 62 00 Load tilter   WS01.00-P-0102B
    IMPORTANTCommercially available devices/tools 
Engine crane		  
    SPECIAL TOOL Lifting eye Fig 2
54 Remove engine from assembly stand.    
REFER TO SPECIAL TOOLS 000 588 00 31 00 Assembly stand for cars   WS01.00-Z-3028KOB
55 Attach engine to front axle carrier and install engine.   AR01.10-P-2510MNL
CHECK VALUES FOR CRANKCASE

Number Designation Engine 176
BE01.40-P-1001-04C Crankshaft bearing Basic bore diameter mm 68, 500...68, 519
Number 1 mm 68, 500...68, 506
Number 2 mm 68, 506...68, 513
Number 3 mm 68, 513...68, 519
CHECK VALUES FOR CRANKCASE

Number Designation Engine 176
BE01.40-P-1002-04C Basic bore width at fit bearing mm 21, 160...21, 127
CHECK VALUES FOR CONNECTING ROD BOLT

Number Designation Engine 176, 177, 178
BE03.10-P-1001-03A Connecting rod bolts Thread diameter   M 8X1
Shank length When new mm 42, 5
max. mm 43, 3
CHECK VALUES OF CRANKSHAFT

Number Designation Engine 176
BE03.20-P-1001-02J Crankshaft journal Ø Nominal Ø   mm 63, 945...63, 965
Repair stage 1 Blue (B) mm 63, 961...63, 965
Repair stage 2 Yellow (G) mm 63, 957...63, 961
Repair stage 3 Red (R) mm 63, 953...63, 957
Repair stage 4 White (W) mm 63, 949...63, 953
Repair stage 5 Violet (V) mm 63, 945...63, 949
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 176
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 046
Axial measurement when new mm 0, 090...0, 280
CHECK VALUES OF CRANKSHAFT

Number Designation Engine 176
BE03.20-P-1003-02J Connecting rod bearing journal Ø mm 51, 945...51, 965
CONNECTING ROD

Number Designation Engine 176
BA03.10-P-1001-01W Bolt, connecting rod bearing cap to connecting rod Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 ∠° 90
CRANKSHAFT

Number Designation Engine 176
BA03.20-P-1001-01N Side bolt to crankshaft bearing cap M8x35 Stage 1 Nm 20
  Stage 2 ∠° 90
M8x50 Stage 1 Nm 25
  Stage 2 ∠° 90
CRANKSHAFT

Number Designation Engine 176
BA03.20-P-1002-01N Bolt, crankshaft bearing cap to crankcase M9 Stage 1 Nm 25
  Stage 2 ∠° 90
M10 Stage 1 Nm 5
  Stage 2 Nm 35
  Stage 3 ∠° 90
Fig 1: Identifying Dial Gage (001 589 53 21 00)
G12816444Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Lifting Eye (177 589 00 62 00)
G13655191Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Mount Dial Indicator (001 589 93 21 00)
G14785852Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Dial Indicator Holder (363 589 02 21 00)
G12816446Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
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