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

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Engine 264 in model 205, 253

MODIFICATION NOTES

08.05.2019	Method description adapted	Operation steps 1.1, 1.2, 2, 72, 73.1, 73.2
30.07.2019	Operation steps changed to operation step variants.	Operation steps 37.1, 37.2, 39.1, 39.2, 42.1, 42.2, 44.1, 44.2, 51.1, and 51.2

Courtesy of MERCEDES-BENZ USA

	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
	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
	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
	Remove
1.1	Remove engine with transmission.	Engine 264 in model 205, 253 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2401MRI
1.2	Remove engine with front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRI
2	Remove engine from front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRI
3	Remove the rear radial shaft sealing ring.		AR03.20-P-3003MRI
4	Attach engine to assembly stand.
	000 588 00 31 00 Assembly stand for cars		WS01.00-Z-3028KOB
5	Remove engine crane with load tilter from engine.
	000 588 00 62 00 Load tilter	Commercially available devices/tools Engine crane	WS01.00-P-0102B
6	Remove hydraulic valve play compensation elements.		AR05.00-P-2011MRI
7	Remove timing case cover.		AR01.40-P-8000MRI
8	Remove timing chain from the timing chain drive gear (8).
9	Remove oil pump.		AR18.10-P-6020MRI
10	Remove oil pump chain from timing chain drive gear (8).
11	Remove timing chain drive gear (8) from crankshaft (1).
12	Remove balance shaft housing.	Engine 264 in model 253 Engine 264.920 in model 205	AR03.20-P-1105MRI
13	Remove front oil deflector.
14	Screw in center bolt of crankshaft (1).	Socket wrench bit	Fig 3
15	Mark installation position on the connecting rod bearing caps and connecting rods.	Do not mix up the connecting rod bearing caps. Engine damage can occur otherwise.
16	Remove the connecting rod bolts and connecting rod bearing cap.	The connecting rods and the connecting rod bearing caps are cracked (broken). Do not mix up connecting rods. Engine damage can occur otherwise. While turning crankshaft (1), make sure that connecting rods do not cant. Crankshaft (1) and connecting rod will otherwise be damaged.
17	Mark the connecting rod bearing shells relative to the associated connecting rod and connecting rod bearing cap.	Only where connecting rod bearing shells are reused. Do not mix up the connecting rod bearing shells. Engine damage can occur otherwise.
18	Remove the connecting rod bearing shells.
19	Determine crankshaft main bearing end play.		AR03.20-P-4291-03MRH
	000 588 00 31 00 Assembly stand for cars		WS01.00-Z-3028KOB
		Crankshaft bearing clearance	*BE03.20-P-1001-04H
		Dial Gauge	Fig 1
		Dial indicator holder If the maximum value of the crankshaft main bearing end play is exceeded, ↓ replace bottom thrust plates (4) and top thrust plates (7) and perform check again. If the maximum value of the crankshaft main bearing end play is exceeded again, ↓ replace crankshaft (1), bottom crankshaft bearing shells (5), top crankshaft bearing shells (6), connecting rod bearing shells, and crankcase.	Fig 2
20	Mark crankshaft bearing caps (2, 3) relative to the crankcase.	Do not swap the crankshaft bearing caps (2, 3) with each other. Engine damage can occur otherwise. The crankshaft bearing caps (2, 3) and crankcase are produced together.
21	Remove screws of the crankshaft bearing caps (2, 3) in reverse order to the tightening specification.	Tightening specification for crankshaft bearing cap screws	AR03.20-P-4351-06MRH
22	Remove crankshaft bearing caps (2, 3).
23	Mark bottom crankshaft bearing shells (5) relative to the respective crankshaft bearing caps (2, 3).	Only when reusing the bottom crankshaft bearing shells (5).
24	Mark bottom thrust plates (4) relative to the crankshaft bearing cap (3).	Only when reusing the bottom thrust plates (4).
25	Remove bottom crankshaft bearing shells (5) from the crankshaft bearing caps (2, 3).
26	Remove bottom thrust plates (4) from the crankshaft bearing cap (3).
27	Remove crankshaft (1) from the crankcase.
28	Mark upper crankshaft bearing shells (6) relative to the crankcase.	Only when reusing top crankshaft bearing shells (6).
29	Mark upper thrust plates (7) relative to crankcase.	Only when reusing the top thrust plates (7).
30	Remove upper crankshaft bearing shells (6) and upper thrust plates (7) from the crankcase.
	Clean
31	Clean all parts of the crank assembly.	The parts of the crank assembly must be absolutely free of soiling. Engine damage can occur otherwise. Assembly cleaner	*BR00.45-Z-1028-04A
	Check
32	Check crankshaft (1) and crankcase.	Where crankshaft (1) or crankcase are reused. Commercially available devices/tools Outside micrometer Quick calipers for internal measurements	AR03.20-P-4463-01MRH
		Bolt for crankshaft bearing cap	*BA03.20-P-1001-01O
		Crankshaft journal width at fit bearing	*BE03.20-P-1002-02M
		Crankshaft journal Ø	*BE03.20-P-1001-02M
		Permissible out-of-roundness and conicity of basic bore	*BE01.40-P-1003-04D
		Basic bore width at fit bearing	*BE01.40-P-1002-04D
		Crankshaft bearing	*BE01.40-P-1001-04D
		Dial Gauge	Fig 1
33	Check lower crankshaft bearing shells (5), upper crankshaft bearing shells (6), lower thrust plates (4), upper thrust plates (7), 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 (5), upper crankshaft bearing shells (6), lower thrust plates (4), upper thrust plates (7) and crankshaft (1).	AH03.20-P-1000-02MM
34	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 connecting rod bearing shells and/or crankshaft (1).	AH03.10-P-0001-03MM
	Install
35	Assign new upper crankshaft bearing shells (6) and new lower crankshaft bearing shells (5).	Only when installing new top crankshaft bearing shells (6) and bottom crankshaft bearing shells (5).	AR03.20-P-4360-01MRH
36.1	Insert new upper crankshaft bearing shells (6) in the crankcase.	Only when replacing the top crankshaft bearing shells (6).	AR03.20-P-4341-03MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
36.2	Insert previously marked top crankshaft bearing shells (6) at the respectively marked location in the crankcase.	Only when reusing top crankshaft bearing shells (6).	AR03.20-P-4341-03MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
37	Wet upper thrust plates (7) with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
38.1	Position new upper thrust plates (7) on crankcase.	Only when installing new top thrust plates (7).
38.2	Position previously marked upper thrust plates (7) at respectively marked location on the crankcase.	Only when reusing the top thrust plates (7).
39	Wet crankshaft journals with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
40	Position crankshaft (1) in crankcase.
41.1	Insert new bottom crankshaft bearing shells (5) in the crankshaft bearing caps (2, 3).	Only when installing new bottom crankshaft bearing shells (5).	AR03.20-P-4341-03MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
41.2	Insert previously marked bottom crankshaft bearing shells (5) in the respectively marked crankshaft bearing cap (2, 3).	Only when reusing the bottom crankshaft bearing shells (5).	AR03.20-P-4341-03MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
42	Wet lower thrust plates (4) with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
43.1	Insert new bottom thrust plates (4) at the crankshaft bearing cap (3).	Only when installing new bottom thrust plates (4).
43.2	Insert previously marked bottom thrust plates (4) at the respectively marked location on the crankshaft bearing cap (3).	Only when reusing the bottom thrust plates (4).
44	Install crankshaft bearing cap (2, 3) at the respectively marked location in the crankcase. Interference fit of crankshaft bearing cap	Install crankshaft bearing cap (2, 3) at the same location and in the same direction as before. Engine damage can occur otherwise.	AH03.20-P-4351-02MM
45	Wet bolt heads of the new bolts of the crankshaft bearing caps (2, 3) with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview	Replace screws.	BB00.40-P-0223-02A
46	Screw in new screws of the crankshaft bearing caps (2, 3) and tighten.	Tightening specification for crankshaft bearing cap screws	AR03.20-P-4351-06MRH
		Bolt for crankshaft bearing cap	*BA03.20-P-1001-01O
	Check
47	Turn crankshaft (1) by hand and check for unobstructed movement of the crank assembly.	While turning crankshaft (1), make sure that connecting rods do not cant. Crankshaft (1) and connecting rod will otherwise be damaged. If the crankshaft (1) is sluggish or stuck: ↓ check for correct use and seating of top crankshaft bearing shells (6) and lower crankshaft bearing shells (5). Assign crankshaft bearing shells	AR03.20-P-4360-01MRH
		Install crankshaft main bearing	AR03.20-P-4341-03MRH
		Specified engine oils for Cars, Vans (service) - Overview	BB00.40-P-0223-02A
48	Check the connecting rod bolts and replace if necessary.		AR03.10-P-6111-01MRH
		Connecting rod bolts	*BE03.10-P-1001-03K
49	Assign new connecting rod bearing shells.	Only where connecting rod bearing shells are replaced.	AR03.10-P-6112-01MRH
50.1	Install new connecting rod bearing shells.	Only where connecting rod bearing shells are replaced.	AR03.10-P-6111-08MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
50.2	Install previously marked connecting rod bearing shells at respectively marked location.	Only where connecting rod bearing shells are reused.	AR03.10-P-6111-08MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
51	Tighten the connecting rod bolts.		AR03.10-P-6111-02MRH
		Bolt, connecting rod bearing cap to connecting rod	*BA03.10-P-1001-01X
	Check
52	Turn crankshaft (1) by hand and check for unobstructed movement of the crank assembly.	Socket wrench bit If the crankshaft (1) is sluggish or stuck: ↓ Check for correct use and seating of the connecting rod bearing shells.	Fig 3
		Assign connecting rod bearing shells	AR03.10-P-6112-01MRH
		Mount connecting rod bearing	AR03.10-P-6111-08MRH
		Specified engine oils for Cars, Vans (service) - Overview	BB00.40-P-0223-02A
53	Unscrew center bolt of crankshaft (1).	Socket wrench bit	Fig 3
54	Install front oil deflector.	Screw/bolt, oil deflector to crankcase	*BA18.10-P-1005-01W
55	Install balance shaft housing.	Engine 264 in model 253 Engine 264.920 in model 205 Install oil pan only after installation of the oil pump.	AR03.20-P-1105MRI
56	Slide timing chain drive gear (8) onto crankshaft (1).	Ensure correct seating of the fitted spring. Engine damage can occur otherwise.
57	Lay oil pump chain on timing chain drive gear (8).
58	Install oil pump.		AR18.10-P-6020MRI
59	Lay timing chain on timing chain drive gear (8).
60	Install timing case cover.		AR01.40-P-8000MRI
61	Install hydraulic valve play compensation elements.		AR05.00-P-2011MRI
62	Install camshafts.		AR05.20-P-6992MRI
63	Attach load tilter to all existing engine lifting lugs and engine crane.
	000 588 00 62 00 Load tilter	Commercially available devices/tools Engine crane	WS01.00-P-0102B
64	Remove engine from assembly stand.
	000 588 00 31 00 Assembly stand for cars		WS01.00-Z-3028KOB
65	Install new rear radial shaft sealing ring.		AR03.20-P-3003MRI
66	Attach engine to front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRI
67.1	Install engine with transmission.	Engine 264 in model 205, 253 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2401MRI
67.2	Install engine with front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRI

CHECK VALUES FOR CRANKCASE

Number	Designation			Engine 264
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 CRANKCASE

Number	Designation		Engine 264
BE01.40-P-1002-04D	Basic bore width at fit bearing	mm	19, 967...20, 000

CHECK VALUES FOR CRANKCASE

Number	Designation		Engine 264
BE01.40-P-1003-04D	Permissible out-of-roundness and conicity of basic bore	mm	0, 03

CHECK VALUES FOR CONNECTING ROD BOLTS

Number	Designation				Engine 264
BE03.10-P-1001-03K	Connecting rod bolts	Thread diameter		M	7 x 1
		Shank length	When new	mm	38
		Shank length	max.	mm	38, 4

CHECK VALUES OF CRANKSHAFT

Number	Designation				Engine 264.915	Engine 264.920
BE03.20-P-1001-02M	Crankshaft journal Ø	Nominal Ø		mm	54, 940...54, 965	54, 940...54, 965
		Repair stage 1	Blue (B)	mm	54, 960...54, 965	54, 960...54, 965
		2nd repair stage	Yellow (G)	mm	54, 955...54, 960	54, 955...54, 960
		Repair stage 3	Red (R)	mm	54, 950...54, 955	54, 950...54, 955
		Repair stage 4	White (W)	mm	54, 945...54, 950	54, 945...54, 950
		Repair stage 5	Violet (V)	mm	54, 940...54, 945	54, 940...54, 945

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 264
BE03.20-P-1001-04H	Crankshaft bearing clearance	Radial measurement when new	mm	0, 019...0, 043
BE03.20-P-1001-04H	Crankshaft bearing clearance	Axial measurement when new	mm	0, 120...0, 300

CHECK VALUES OF CRANKSHAFT

Number	Designation			Engine 264.915	Engine 264.920
BE03.20-P-1002-02M	Crankshaft journal width at fit bearing	Marking N colorless (0)	mm	24, 550...24, 590	24, 550...24, 590

CONNECTING ROD

Number	Designation				Engine 264
BA03.10-P-1001-01X	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 264
BA03.20-P-1001-01O	Bolt for crankshaft bearing cap	Stage 1	Nm	36
BA03.20-P-1001-01O	Bolt for crankshaft bearing cap	Stage 2	∠°	120

OIL PUMP

Number	Designation		Engine 264
BA18.10-P-1005-01W	Screw/bolt, oil deflector to crankcase	Nm	9

Fig 1: Identifying Dial Gauge (001 589 32 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Dial Indicator Holder (363 589 02 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Socket Wrench Bit (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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