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

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Engine 260 in model 118, 177, 247 

G16048226Courtesy of MERCEDES-BENZ USA
WARNING Risk of injury.  Skin or eye injuries may result when handling hot or glowing objects. Wear protective gloves, protective clothing and safety glasses, if necessary. AS00.00-Z-0002-01A
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 body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
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 bottom timing case cover.   AR01.40-P-8002MFC
2 Remove rear radial shaft sealing ring from crankshaft (6).   AR03.20-P-3064MFC 
3 Remove camshafts.   AR05.20-P-6992MFC
4 Remove timing chain from timing chain drive gear (3).    
5 Remove oil pump.   AR18.10-P-6020MFC
6 Remove oil pump chain from timing chain drive gear (3).    
7 Remove balance shaft housing.   AR03.20-P-1105MFC 
8 Remove timing chain drive gear (3) from crankshaft (6).    
9 Screw center bolt of the belt pulley into crankshaft (6). SPECIAL TOOL Socket wrench bit Fig 5
10 Mark installation position on the 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 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 While turning the crankshaft (6) ensure that connecting rods do not get tilted.		  
12 Mark connecting rod bearing shells relative to the 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 end play of crankshaft main bearing.    
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
      AR03.20-P-4291-03MR 
    HELD TESTER Crankshaft bearing clearance *BE03.20-P-1001-04H 
    SPECIAL TOOL Dial indicator holder Fig 4
    SPECIAL TOOL Mount dial indicator
If the maximum value of the crankshaft main bearing end play is exceeded:
↓
Replace lower thrust plates (A) and upper thrust plates (B) and perform check again.
If the maximum value of the crankshaft main bearing end play is exceeded again:
↓
Replace crankshaft (6), bottom crankshaft bearing shells (4), top crankshaft bearing shells (5), connecting rod bearing shells, and crankcase.		 Fig 3
15 Mark crankshaft bearing caps (1) and crankshaft main bearing cap (2) relative to the crankcase. NOTES The crankshaft bearing caps (1), crankshaft main bearing cap (2), and the crankcase are produced together. Do not mix up.
Engine damage can occur otherwise.		  
16 Remove screws of the crankshaft bearing caps (1) and crankshaft main bearing cap (2) in reverse order of the tightening procedure. Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MR 
17 Remove crankshaft bearing caps (1) and crankshaft main bearing cap (2).    
18 Mark bottom crankshaft bearing shells (4) relative to the respective crankshaft bearing caps (1) and crankshaft main bearing cap (2). Only when reusing the lower crankshaft bearing shells (4).  
19 Mark lower thrust plates (A) relative to crankshaft main bearing cap (2). Only when reusing the lower thrust plates (A).  
20 Remove bottom crankshaft bearing shells (4) from crankshaft bearing caps (1) and crankshaft main bearing cap (2).    
21 Remove lower thrust plates (A) from crankshaft main bearing cap (2).    
22 Remove the crankshaft (6) from the crankcase. IMPORTANT Aid of helper required.  
23 Mark the upper crankshaft bearing shells (5) relative to the crankcase. Only if upper crankshaft bearing shells (5) are reused.  
24 Mark upper thrust plates (B) relative to the crankcase. Only when reusing the upper thrust plates (B).  
25 Remove upper crankshaft bearing shells (5) and upper thrust plates (B) from the crankcase.    
26 Clean all parts of crank assembly. NOTES The parts of the crank assembly must be absolutely free of soiling.
Engine damage will occur otherwise.
Assembly cleaner		 *BR00.45-Z-1028-04A 
INSPECT Check     
27 Check crankshaft (6) in the removed state. Only if the crankshaft is reused (6). AR03.20-P-4463-01MR 
    HELD TESTER Crankshaft journal Ø *BE03.20-P-1001-02M 
    HELD TESTER Crankshaft bearing *BE01.40-P-1001-04D 
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap *BA03.20-P-1001-01B 
    SPECIAL TOOL Dial gauge Fig 1
28 Check lower crankshaft bearing shells (4), upper crankshaft bearing shells (5), lower thrust plates (A), upper thrust plates (B), and the crankshaft bearing journals for wear and damage.
Information on assessing wear of main bearings and main bearing journals		 If problems occur:
↓
Install new lower crankshaft bearing shells (4), upper crankshaft bearing shells (5), lower thrust plates (A), upper thrust plates (B), and crankshaft (6).		 AH03.20-P-1000-02 MM 
29 Check connecting rod bearing shells and connecting rod journals for wear and damage.
Notes on assessing wear on connecting rod bearings and connecting rod journals		 If problems occur:
↓
replace the connecting rod bearing shells or crankshaft (6).		 AH03.10-P-0001-03 MM 
INSTALLING Install     
30 Assign new upper crankshaft bearing shells (5) and new lower crankshaft bearing shells (4). Only when replacing the upper crankshaft bearing shells (5) and lower crankshaft bearing shells (4). AR03.20-P-4360-01MR 
31 Wet upper crankshaft bearing shells (5) and upper thrust plates (B) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
32.1 Insert new top crankshaft bearing shells (5) and new top thrust plates (B) in the crankcase. Only when replacing the upper crankshaft bearing shells (5) and upper thrust plates (B).  
32.2 Insert previously marked top crankshaft bearing shells (5) and previously marked top thrust plates (B) in the respectively marked position in the crankcase. Only when reusing the upper crankshaft bearing shells (5) and upper thrust plates (B).  
33 Wet crankshaft bearing journals with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
34 Position crankshaft (6) in the crankcase. IMPORTANT Aid of helper required.  
35 Moisten lower crankshaft bearing shells (4) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
36.1 Insert new bottom crankshaft bearing shells (4) in the crankshaft bearing caps (1) and in the crankshaft main bearing cap (2). Only when installing new lower crankshaft bearing shells (4).  
36.2 Insert previously marked bottom crankshaft bearing shells (4) in the respectively marked crankshaft bearing cap (1) and the marked crankshaft main bearing cap (2). Only when reusing the lower crankshaft bearing shells (4).  
37 Wet lower thrust plates (A) 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 (A) into the crankshaft main bearing cap (2). Only when installing new lower thrust plates (A).  
38.2 Insert the previously marked lower thrust plates (A) for the respectively marked location into the crankshaft main bearing cap (2). Only when reusing the lower thrust plates (A).  
39 Install crankshaft bearing caps (1) and crankshaft main bearing cap (2) at the respectively marked location in the crankcase.
Interference fit of crankshaft bearing cap		 NOTES Install crankshaft bearing caps (1) and crankshaft main bearing cap (2) at the same location and in the same direction as before.
Engine damage can occur otherwise.		 AH03.20-P-4351-02 MM 
40 Wet bolt heads of the new screws of the crankshaft bearing caps (1) and crankshaft main bearing cap (2) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview IMPORTANT Replace screws. BB00.40-P-0223-02A
41 Tighten screws of the crankshaft bearing caps (1) and crankshaft main bearing cap (2). Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MR 
    IMPORTANT Observe tightening procedure.
TORQUE SPECIFICATION Bolt for crankshaft bearing cap		 *BA03.20-P-1001-01B 
42 Turn crankshaft (6) at center bolt of the belt pulley check for and unobstructed movement. NOTES While turning the crankshaft (6) ensure that connecting rods do not get tilted.
Otherwise, the crankshaft (6) and connecting rods will be damaged.		 Fig 5
    SPECIAL TOOL Socket wrench bit
If the crankshaft (6) is sluggish or sticking,
↓
Check for correct use and seating of the upper crankshaft bearing shells (5) and lower crankshaft bearing shells (4).		 AR03.20-P-4360-01MR 
43 Check the connecting rod bolts and replace if necessary.   AR03.10-P-6111-01MFC 
    HELD TESTER Connecting rod bolts *BE03.10-P-1001-03A 
44 Insert connecting rod bearing shells.   AR03.10-P-6111-06MR 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
45 Tighten connecting rod bolts.   AR03.10-P-6111-02MR 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
    TORQUE SPECIFICATION Screw/bolt, connecting rod bearing cap to connecting rod *BA03.10-P-1001-01J 
    SPECIAL TOOL Tightening angle with magnet Fig 2
46 Turn crankshaft (6) at center bolt of the belt pulley check for and unobstructed movement.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
    SPECIAL TOOL Socket wrench bit Fig 5
    If the crankshaft (6) is sluggish or sticking,
↓
Check for correct use and seating of the connecting rod bearing shells.		 AR03.10-P-6111-06MR 
47 Remove center bolt of belt pulley from the crankshaft (6). SPECIAL TOOL Socket wrench bit Fig 5
48 Slide timing chain drive gear (3) onto crankshaft (6). NOTES Ensure correct seating of the fitted spring.
Engine damage can occur otherwise.		  
49 Install balance shaft housing. IMPORTANT Install oil pan only after installation of the oil pump. AR03.20-P-1105MFC 
50 Install oil pump.   AR18.10-P-6020MFC
51 Lay the oil pump chain on timing chain drive gear (3).    
52 Lay timing chain on timing chain drive gear (3).    
53 Install camshafts.   AR05.20-P-6992MFC
54 Install new rear radial shaft sealing ring.   AR03.20-P-3064MFC 
55 Install bottom timing case cover.   AR01.40-P-8002MFC
CHECK VALUES FOR CRANKCASE

Number Designation Engine 260
BE01.40-P-1001-04D Crankshaft bearing Basic bore diameter mm 59, 000...59, 019
Number 1 (blue) mm 59, 000...59, 006
Number 2 (yellow) mm 59, 006...59, 013
Number 3 (red) mm 59, 013...59, 019
CHECK VALUES FOR CONNECTING ROD BOLT

Number Designation Engine 137, 260, 270, 271, 274, 275, 285
BE03.10-P-1001-03A Connecting rod bolts Thread diameter   M 7x1
Shank length When new mm 38
max. mm 38, 4
CHECK VALUES OF CRANKSHAFT

Number Designation Engine 260
BE03.20-P-1001-02M Crankshaft journal Ø Nominal Ø   mm 54, 940...54, 965
Repair stage 1 Blue (B) mm 54, 960...54, 965
Repair stage 2 Yellow (G) mm 54, 955...54, 960
Repair stage 3 Red (R) mm 54, 950...54, 955
Repair stage 4 White (W) mm 54, 945...54, 950
Repair stage 5 Violet (V) mm 54, 940...54, 945
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 260
BE03.20-P-1001-04H Crankshaft bearing clearance Radial measurement when new mm 0, 019...0, 043
Axial measurement when new mm 0, 120...0, 300
CONNECTING ROD

Number Designation Engine 260
BA03.10-P-1001-01J Screw/bolt, connecting rod bearing cap to connecting rod For initial tightening of new bolts Stage 1 Nm 5
Stage 2 Nm 15
Stage 3 ∠° 180
Stage 4   Loosen bolts
Stage 5 Nm 5
Stage 6 Nm 15
Stage 7 ∠° 90
In case of reusability Stage 1 Nm 5
Stage 2 Nm 15
Stage 3 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation Engine 260
BA03.20-P-1001-01B Bolt for crankshaft bearing cap Stage 1 Nm 36
Stage 2 ∠° 120
Fig 1: Identifying Dial Gauge (001 589 53 21 00)
G12816444Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Tightening Angle With Magnet (450 589 00 13 00)
G16054140Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Mount Dial Indicator (001 589 93 21 00)
G14785869Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Dial Indicator Holder (363 589 02 21 00)
G12816446Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Socket Wrench Bit (001 589 65 09 00)
G11971737Courtesy 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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