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

Engine 139 in model 118, 177, 247 

G16048232Courtesy 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 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 transmission.   AR27.10-P-0009MFA
2 Release catalytic converter from exhaust gas turbocharger and remove from engine.   AR49.20-P-0100MFG
3 Attach engine to assembly stand.    
REFER TO SPECIAL TOOLS 000 588 17 31 00 Adapter   WS01.00-P-0202C
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
      AR01.00-P-0002-01MFG
4 Remove timing chain.   AR05.10-P-7602MFG
5 Remove oil pan.   AR01.45-P-7500MFG
6 Mark the 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.		  
7 Remove the connecting rod bolts and connecting rod bearing cap. NOTES The connecting rods and the connecting rod bearing caps are cracked (broken). Do not mix up connecting rods.
Engine damage can occur otherwise.
NOTES While turning crankshaft (1), make sure that connecting rods do not cant.
Crankshaft (1) and connecting rod will otherwise be damaged.
SPECIAL TOOL Socket wrench bit		 Fig 4
8 Mark connecting rod bearing shells relative to associated connecting rod and connecting rod bearing cap. When reusing the connecting rod bearing shells.
NOTES Do not mix up the connecting rod bearing shells.
Engine damage can occur otherwise.		  
9 Remove connecting rod bearing shells.    
10 Determine crankshaft main bearing end play.   AR03.20-P-4291-03MR 
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
    HELD TESTER Crankshaft bearing clearance *BE03.20-P-1001-04H 
    SPECIAL TOOL Mount dial indicator Fig 2
    SPECIAL TOOL Dial indicator holder
If the maximum value of the crankshaft main bearing end play is exceeded:
↓
replace top thrust plates (3) and bottom thrust plates (5) 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 (4), top crankshaft bearing shells (2), connecting rod bearing shells, and crankcase.		 Fig 3
11 Mark crankshaft bearing caps (6, 7) relative to the crankcase. NOTES The crankshaft bearing caps (6, 7) and crankcase are produced together. Do not mix up.
Engine damage can occur otherwise.		  
12 Remove screws of the crankshaft bearing caps (6, 7) in reverse order of the tightening procedure. Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MR 
13 Remove crankshaft bearing caps (6, 7).    
14 Mark bottom crankshaft bearing shells (4) relative to the respective crankshaft bearing caps (6, 7). When reusing the bottom crankshaft bearing shells (4).  
15 Mark bottom thrust plates (5) relative to the crankshaft bearing cap (7). When reusing the bottom thrust plates (5).  
16 Remove the bottom crankshaft bearing shells (4) from the crankshaft bearing caps (6, 7).    
17 Remove bottom thrust plates (5) from the crankshaft bearing cap (7).    
18 Remove crankshaft (1) from the crankcase.    
19 Mark top crankshaft bearing shells (2) relative to the crankcase. When reusing the top crankshaft bearing shells (2).  
20 Mark top thrust plates (3) relative to crankcase. Only when reusing the top thrust plates (3).  
21 Remove top crankshaft bearing shells (2) and top thrust plates (3) from the crankcase.    
22 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     
23 Check crankshaft (1) and crankcase for wear. When reusing the crankshaft (1) or the crankcase.
IMPORTANTCommercially available devices/tools 
Outside micrometer
Quick calipers for internal measurements		 AR03.20-P-4463-01MR 
    HELD TESTER Permissible out-of-roundness and conicity of basic bore *BE01.40-P-1003-04D 
    HELD TESTER Basic bore width at fit bearing *BE01.40-P-1002-04D 
    HELD TESTER Crankshaft bearing *BE01.40-P-1001-04D 
    HELD TESTER Crankshaft journal width at fit bearing *BE03.20-P-1002-02O 
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap *BA03.20-P-1001-01B 
    HELD TESTER Crankshaft journal Ø *BE03.20-P-1001-02O 
    SPECIAL TOOL Mount dial indicator
If there are problems:
↓
replace crankcase or crankshaft (1).		 Fig 2
24 Check bottom crankshaft bearing shells (4), top crankshaft bearing shells (2), bottom thrust plates (5), top thrust plates (3), and the crankshaft bearing journals for wear and damage.
Information on assessing wear of main bearings and main bearing journals		   AH03.20-P-1000-02 MM 
    If problems occur:
↓
Install new bottom crankshaft bearing shells (4), top crankshaft bearing shells (2), bottom thrust plates (5), top thrust plates (3), and crankshaft (1).
Assign crankshaft bearing shells		 AR03.20-P-4360-01MFG 
25 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		   AH03.10-P-0001-03 MM 
    If problems occur:
↓
Replace connecting rod bearing shells and/or crankshaft (1).
Install and gauge connecting rod bearings		 AR03.10-P-6111-06MR 
26 Check the connecting rod bolts and replace if necessary.   AR03.10-P-6111-01MFG 
    HELD TESTER Connecting rod bolts *BE03.10-P-1001-03A 
INSTALLING Install     
27 Assign top crankshaft bearing shells (2) and bottom crankshaft bearing shells (4). When installing new top crankshaft bearing shells (2) and bottom crankshaft bearing shells (4).
Assign crankshaft bearing shells		 AR03.20-P-4360-01MFG 
28.1 Wet top crankshaft bearing shells (2) with engine oil and insert in the crankcase. When installing new top crankshaft bearing shells (2).  
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
28.2 Wet previously marked top crankshaft bearing shells (2) with engine oil and insert at the respectively marked location in the crankcase. When reusing the top crankshaft bearing shells (2).  
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
29 Wet top thrust plates (3) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
30.1 Position top thrust plates (3) on the crankcase. When installing new top thrust plates (3).  
30.2 Position previously marked upper thrust plates (3) at respectively marked location on the crankcase. When reusing the top thrust plates (3).  
31 Wet crankshaft journals with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
32 Position crankshaft (1) in crankcase.    
33.1 Wet bottom crankshaft bearing shells (4) with engine oil and insert into the crankshaft bearing caps (6, 7). When installing new bottom crankshaft bearing shells (4).  
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
33.2 Wet previously marked bottom crankshaft bearing shells (4) with engine oil and insert into the respectively marked crankshaft bearing cap (6, 7). When reusing the bottom crankshaft bearing shells (4).  
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
34 Wet bottom thrust plates (5) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
35.1 Insert thrust plates (5) at the crankshaft bearing cap (7). When installing new bottom thrust plates (5).  
35.2 Insert previously marked bottom thrust plates (5) at the respectively marked location on the crankshaft bearing cap (7). When reusing the bottom thrust plates (5).  
36 Install crankshaft bearing caps (6, 7) at the respectively marked location in the crankcase. NOTES Install crankshaft bearing caps (6, 7) at the same location and in the same direction as before.
Engine damage can occur otherwise.		  
37 Wet bolt heads of the screws of the crankshaft bearing caps (6, 7) with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview IMPORTANT Replace screws. BB00.40-P-0223-02A
38 Screw in screws of the crankshaft bearing caps (6, 7) and tighten according to the tightening procedure. Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MR 
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap *BA03.20-P-1001-01B 
39 Turn crankshaft (1) by hand and check for unobstructed movement of the crank assembly. NOTES While turning crankshaft (1), make sure that connecting rods do not cant.
Crankshaft (1) and connecting rod will otherwise be damaged.
SPECIAL TOOL Socket wrench bit		 Fig 4
    If the crankshaft (1) is sluggish or stuck:
↓
check for correct use and seating of the top crankshaft bearing shells (2) and bottom crankshaft bearing shells (4).
Assign crankshaft bearing shells		 AR03.20-P-4360-01MFG 
REFER TO CAPACITIES & SPECIFICATIONS   Specified engine oils for Cars, Vans (service) - Overview BB00.40-P-0223-02A
40 Assign connecting rod bearing shells. When replacing 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
41.1 Install connecting rod bearing shells. When replacing 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
41.2 Install previously marked connecting rod bearing shells at respectively marked location. When reusing the 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
42 Tighten the connecting rod bolts.   AR03.10-P-6111-02MFG 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
    TORQUE SPECIFICATION Connecting rod bolt *BA03.10-P-1001-01E 
    SPECIAL TOOL Tightening angle with magnet Fig 1
43 Turn crankshaft (1) by hand and check for unobstructed movement of the crank assembly. SPECIAL TOOL Socket wrench bit Fig 4
    If the crankshaft (1) is sluggish or stuck:
↓
Check for correct use and seating of the connecting rod bearing shells.
Install and gauge connecting rod bearings		 AR03.10-P-6111-06MR 
REFER TO CAPACITIES & SPECIFICATIONS   Specified engine oils for Cars, Vans (service) - Overview BB00.40-P-0223-02A
44 Install oil pan.   AR01.45-P-7500MFG
45 Install timing chain.   AR05.10-P-7602MFG
46 Remove engine from assembly stand and position on the lifting platform.   AR01.00-P-0002-01MFG
REFER TO SPECIAL TOOLS 000 588 17 31 00 Adapter   WS01.00-P-0202C
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
REFER TO SPECIAL TOOLS 000 588 25 62 00 Lift table IMPORTANT Helper required. WS01.00-P-0264A
47 Attach catalytic converter to the engine.   AR49.20-P-0100MFG
48 Install transmission.   AR27.10-P-0009MFA
CHECK VALUES FOR CRANKCASE

Number Designation Engine 139
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 139
BE01.40-P-1002-04D Basic bore width at fit bearing mm 19, 967...20, 000
CHECK VALUES FOR CRANKCASE

Number Designation Engine 139
BE01.40-P-1003-04D Permissible out-of-roundness and conicity of basic bore mm 0, 03
CHECK VALUES FOR CONNECTING ROD BOLT

Number Designation Engine 133, 139
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 139
BE03.20-P-1001-02O 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 139
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
CHECK VALUES OF CRANKSHAFT

Number Designation Engine 139
BE03.20-P-1002-02O Crankshaft journal width at fit bearing Marking N Colorless mm 24, 550...24, 590
CONNECTING ROD

Number Designation Engine 139
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation Engine 139
BA03.20-P-1001-01B Bolt for crankshaft bearing cap Stage 1 Nm 40
Stage 2 ∠° 90
Fig 1: Identifying Tightening Angle With Magnet (450 589 00 13 00)
G16054140Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Mount Dial Indicator (001 589 93 21 00)
G14785869Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Dial Indicator Holder (363 589 02 21 00)
G12816446Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Socket Wrench Bit (001 589 65 09 00)
G11972630Courtesy 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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