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Replace crankcase - AR01.40-P-8400AMG

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ENGINE 156 

MODIFICATION NOTES

14.9.09 Value changed: main bearing play, radial - new value   BE03.20-P-1001-04E
14.9.09 Value changed: main bearing play, axial - new value   BE03.20-P-1001-04E
14.9.09 Value changed: connecting rod bearing play   BE03.20-P-1002-04E
14.9.12 cylinder crankcase - Lower part of the cylinder crankcase - upper part   BA03.20-P-1002-01J

Shown on model 219.377 

Fig 1: Crankcase Components - Shown On Model 219.377 (1 Of 4)
G09973923Courtesy of MERCEDES-BENZ USA
Fig 2: Crankcase Components - Shown On Model 219.377 (2 Of 4)
G09973924Courtesy of MERCEDES-BENZ USA
Fig 3: Crankcase Components - Shown On Model 219.377 (3 Of 4)
G09973925Courtesy of MERCEDES-BENZ USA
Fig 4: Crankcase Components - Shown On Model 219.377 (4 Of 4)
G09973926Courtesy of MERCEDES-BENZ USA
INSPECT Check     
1 Check package contents for cylinder crankcase (7, 8) IMPORTANT The following parts are contained in the package contents:
Piston with piston rings
Upper bearing shell (1)
Knock sensors (A16/1, A16/2)
Crankshaft position sensor (L5) (except model 204) Crankshaft Hall sensor (B70) (model 204) Crankcase ventilation system (12)
Stop plug (13)
Oil thermostat
Bearing sleeve intermediate gear (16)
Dowel pins (10) for tensioning rails and slide rails		  
REMOVING Remove     
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
2 Remove pistons   AR03.10-P-7021AMG
3 Detach connecting rods from piston If reusing the connecting rods  
4 Remove timing case cover   AR01.40-P-8000AMG 
5 Remove tensioning rails and slide rails for the timing chain MODEL 204, 212 with ENGINE 156 AR05.10-P-8500CMG
MODEL 164, 251 with ENGINE 156 AR05.10-P-8500GZS
MODEL 230.470 with ENGINE 156 AR05.10-P-8500RMG
MODEL 216, 221 with ENGINE 156 AR05.10-P-8500SMG
MODEL 209.377/477 with ENGINE 156.982
MODEL 211.077/277, 219.377 with ENGINE 156.983		 AR05.10-P-8500TMG
6 Take off timing chain    
7 Detach intermediate gear for timing chain from the bearing sleeve (16) IMPORTANT Check intermediate gear for wear and damage; replace if necessary.  
8 Detach right and left engine support from cylinder crankcase (7, 8) Remove model 211.077/277, 219.377 with engine 156.983 engine support on the right AR22.10-P-4340TY
Remove model 211.077/277, 219.377 with engine 156.983 engine support on the right AR22.10-P-4350TY
MODEL 204, 212 with ENGINE 156 AR22.10-P-1260CMG
MODEL 164, 251 with ENGINE 156 AR22.10-P-1260GZS
MODEL 209.377/477 with ENGINE 156.982 AR22.10-P-1260QMG
MODEL 230.470 with ENGINE 156 AR22.10-P-1260RMG
MODEL 216 with ENGINE 156
MODEL 221 with ENGINE 156		 AR22.10-P-1260SX
9 Remove crankshaft (15)   AR03.20-P-4351AMG
10 Remove fit bolts (5) and take off oil spray nozzles (6) IMPORTANT The oil spray nozzles must be replaced if there is bearing damage. AR18.00-P-4000AMG
11 Detach engine cable harness from cylinder crankcase (7, 8)    
CLEAN Clean     
12 Clean sealing surfaces   AR01.00-P-0050-01A
NOTES Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.		  
Loctite 7200 *BR00.45-Z-1038-04A 
Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
INSTALLING Install     
13 Position oil spray nozzles (6) and screw in fit bolts (5)   AR18.00-P-4000AMG
14 Install crankshaft (15) ENGINE 156.980/981/982/983/984/985 AR03.20-P-4351AMG
Mount crankshaft bearing and measure if necessary.
↓
Install/gauge crankshaft bearings		 AR03.20-P-4341-01AMG
Main bearing play *BE03.20-P-1001-04E 
Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm *BE03.20-P-1001-03J 
TORQUE SPECIFICATION Cylinder crankcase lower part to cylinder crankcase upper part *BA03.20-P-1002-01J 
TORQUE SPECIFICATION Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection) *BA03.20-P-1001-01J 
Crankshaft journal width at fit bearing *BE03.20-P-1002-02I 
Crankshaft journal dia. *BE03.20-P-1001-02I 
Main bearing shells standard dimension for bearing cap ø 67.950/67.966 mm *BE03.20-P-1004-03J 
Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm *BE03.20-P-1003-03J 
Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm *BE03.20-P-1002-03J 
15 Mount connecting rod on piston Connecting rod bearing play *BE03.20-P-1002-04E 
16 Install pistons   AR03.10-P-7021AMG
17 Mount right and left engine support on cylinder crankcase (7, 8) Install model 211.077/277, 219.377 with engine 156.983 engine support on the right AR22.10-P-4340TY
Install model 211.077/277, 219.377 with engine 156.983 engine support on the right AR22.10-P-4350TY
MODEL 204, 212 with ENGINE 156 AR22.10-P-1260CMG
MODEL 164, 251 with ENGINE 156 AR22.10-P-1260GZS
MODEL 209.377/477 with ENGINE 156.982 AR22.10-P-1260QMG
MODEL 230.470 with ENGINE 156 AR22.10-P-1260RMG
MODEL 216 with ENGINE 156
MODEL 221 with ENGINE 156		 AR22.10-P-1260SX
18 Detach centering sleeves on control side of the cylinder crankcase (7, 8)    
19 Mount intermediate gear for timing chain with bearing sleeve (16) on the upper cylinder crankcase (7) IMPORTANT Replace intermediate gear cap.  
20 Install tensioning rails and slide rails for the timing chain MODEL 204, 212 with ENGINE 156 AR05.10-P-8500CMG
MODEL 164, 251 with ENGINE 156 AR05.10-P-8500GZS
MODEL 230.470 with ENGINE 156 AR05.10-P-8500RMG
MODEL 216, 221 with ENGINE 156 AR05.10-P-8500SMG
MODEL 209.377/477 with ENGINE 156.982
MODEL 211.077/277, 219.377 with ENGINE 156.983		 AR05.10-P-8500TMG
21 Fit on timing chain    
22 Mount engine cable harness on cylinder crankcase (7, 8) IMPORTANT Ensure correct routing of the motor cable harness on the cylinder crankcase.  
23 Install timing case cover   AR01.40-P-8000AMG 
IMPORTANT Notes on sealant path for timing case cover   AH01.40-P-1000-01AMG
IMPORTANT Replace crankshaft radial sealing ring, coolant passage seal and radial sealing ring for oil centrifuge.
Note different bolt lengths:
↓
Bolt plan for timing case cover		 AR01.40-P-8000-01AMG 
TORQUE SPECIFICATION Bolt, coolant pump to timing case cover/crankcase *BA20.10-P-1001-01V 
TORQUE SPECIFICATION Screw/bolt, timing case cover to cylinder crankcase *BA01.40-P-1001-01W 
TORQUE SPECIFICATION Screw/bolt, cylinder head bolt to timing case cover chain box on outside *BA01.40-P-1002-01W 
TORQUE SPECIFICATION Cylinder head to timing case chain box on inside *BA01.40-P-1003-01W 
Loctite 5970 sealant *BR00.45-Z-1013-01A 
Assembly cleaner *BR00.45-Z-1028-04A 
SPECIAL TOOL Application gun Figure
SPECIAL TOOL Drift Figure
CHECK VALUES OF CRANKSHAFT

Number Designation ENGINE 156
BE03.20-P-1001-02I Crankshaft journal dia. Nominal dia. mm 67, 950...67, 965
Repair stage 1 Blue (B) mm 67, 962...67, 965
Repair stage 2 Yellow (y) mm 67, 958...67, 962
Repair stage 3 Red (R) mm 67, 954...67, 958
Repair stage 4 Green (g) mm 67, 950...67, 954
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156
BE03.20-P-1001-03J Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm Replacement part additional number colored marking blue (b)=1 52
Bearing shell thickness mm 2, 255...2, 259
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation ENGINE 156
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 041
Axial measurement when new mm 0, 15...0, 316
CHECK VALUES OF CRANKSHAFT

Number Designation ENGINE 156
BE03.20-P-1002-02I Crankshaft journal width at fit bearing Marking N/0 mm 27, 900...29, 933
Marking N1/1 mm 28, 000...28, 033
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156
BE03.20-P-1002-03J Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm Replacement part additional number colored marking yellow (y)=2 54
Bearing shell thickness mm 2, 259...2, 263
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation ENGINE 156
BE03.20-P-1002-04E Connecting rod bearing play Radial measurement when new mm 0, 028...0, 063
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156
BE03.20-P-1003-03J Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm Replacement part additional number colored marking red (r)=3 56
Bearing shell thickness mm 2, 263...2, 267
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156
BE03.20-P-1004-03J Main bearing shells standard dimension for bearing cap Ø 67.950/67.966 mm Replacement part additional number (color coding green (g)=4 59
Bearing shell thickness mm 2, 267...2, 271
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number Designation ENGINE 156
BA01.40-P-1001-01W Screw/bolt, timing case cover to cylinder crankcase M8 Nm 20
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number Designation ENGINE 156
BA01.40-P-1002-01W Screw/bolt, cylinder head bolt to timing case cover chain box on outside M8 Nm 20
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number Designation ENGINE 156
BA01.40-P-1003-01W Cylinder head to timing case chain box on inside M8 Nm 20
CRANKSHAFT BEARING CAP

Number Designation ENGINE 156
BA03.20-P-1001-01J Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection) M9 Stage 1 Nm 20
Stage 2 Nm 32
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 losen
Stage 6 Nm 20
Stage 7 Nm 32
Stage 8 ∠° 90
Stage 9 ∠° 90
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 ∠° 90
Stage 4 ∠° 90
Stage 5 losen
Stage 6 Nm 20
Stage 7 Nm 40
Stage 8 ∠° 90
Stage 9 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 156
BA03.20-P-1002-01J Cylinder crankcase lower part to cylinder crankcase upper part M6 Stage 1 Nm 4
Stage 2 ∠° 90
M8 Stage 1 Nm 10
Stage 2 ∠° 90
COOLANT PUMP, COOLANT THERMOSTAT

Number Designation ENGINE 156
BA20.10-P-1001-01V Bolt, coolant pump to timing case cover/crankcase M6X30 Nm 9
M6X80 Nm 9
M8X80 Nm 20
M8X100 Nm 20
Fig 5: Identifying Application Gun (112 589 00 25 00)
G09973927Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Drift (156 589 00 15 00)
G09973928Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Loctite 5970 sealant A 003 989 98 20
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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