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Remove/install crankshaft - AR03.20-P-4351AMG

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ENGINE 156.980/981/982/983/984/985 

MODIFICATION NOTES

1.2.12 Value changed: connecting rod bearing cap on the connecting rod, stage 3   BA03.10-P-1001-01Q
29.2.12 Connecting rod cap to the connecting rod   BA03.10-P-1001-01Q
22.3.12 Connecting rod cap to the connecting rod   BA03.10-P-1001-01Q
Fig 1: Crankshaft Remove/Install Components (1 Of 2)
G09974122Courtesy of MERCEDES-BENZ USA
Fig 2: Crankshaft Remove/Install Components (2 Of 2)
G09974123Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1.1 Remove engine with front axle carrier MODEL 164, 251 with ENGINE 156.980  
      AR01.10-P-2500GZS
1.2 Remove engine ENGINE 156.981 in MODEL 230
ENGINE 156.982 in MODEL 209
ENGINE 156.983 in MODEL 211
ENGINE 156.983 in MODEL 219
ENGINE 156.984 in MODEL 216
ENGINE 156.984 in MODEL 221
ENGINE 156.985 in MODEL 204		  
    MODEL 204 with ENGINE 156 AR01.10-P-2400CMG
    MODEL 209.377/477 with ENGINE 156.982 AR01.10-P-2400QMG
    MODEL 211.077/277, 219.377 with ENGINE 156.983 AR01.10-P-2400TMG
    MODEL 216, 221 with ENGINE 156 AR01.10-P-2400SMG
    MODEL 230.470 with ENGINE 156.981 AR01.10-P-2400RMG
2 Remove engine from front axle carrier ENGINE 156.980 in MODEL 164, 251  
      AR01.10-P-2510GZS
3 Detach transmission from engine    
4 Remove oil lines from automatic transmission at oil pan    
5 Mount engine onto assembly stand    
6 Remove spark plugs Only if it is not possible to crank engine due to high compression.  
    MODEL 164, 251 with ENGINE 156.980 AR15.12-P-1010GZS
    MODEL 204, 212 with ENGINE 156.985 AR15.12-P-1010CMG
    MODEL 209.377/477 with ENGINE 156.982
MODEL 211.077/277, 219.377 with ENGINE 156.983		 AR15.12-P-1010TMG
    MODEL 216, 221 with ENGINE 156.984 AR15.12-P-1010SMG
    MODEL 230.470 with ENGINE 156.981 AR15.12-P-1010RMG
7 Turn engine at crankshaft (5) in direction of engine rotation to a 40° crank angle after ignition TDC and check position of camshafts   AR05.20-P-6010-01AMG
    IMPORTANT Rotate engine at crankshaft (5) in direction of engine rotation until the 40° marking on belt pulley/vibration damper corresponds with marking on timing case cover.  
8 Remove timing case cover   AR01.40-P-8000AMG
    NOTES
Do not damage cylinder head gaskets. Leaks and engine damage can occur otherwise.		  
9 Remove flywheel/drive plate MODEL 164, 251 with ENGINE 156.980 with TRANSMISSION 722 AR03.30-P-8001GZS
    MODEL 204, 212 with ENGINE 156.985 AR03.30-P-8001CMG 
    MODEL 209.377/477 with ENGINE 156.982
MODEL 211.077/277, 219.377 with ENGINE 156.983		 AR03.30-P-8001TMG
    MODEL 216, 221 with ENGINE 156.984 with TRANSMISSION 722 AR03.30-P-8001SMG
    MODEL 230.470 with ENGINE 156.981 AR03.30-P-8001RMG
10 Remove oil pump MODEL 164, 251 with ENGINE 156.980 AR18.10-P-6020GZS
    MODEL 204, 212 with ENGINE 156.985 AR18.10-P-6020CMG
    MODEL 209.377/477 with ENGINE 156.982
MODEL 211.077/277, 219.377 with ENGINE 156.983		 AR18.10-P-6020TMG
    MODEL 216, 221 with ENGINE 156.984 AR18.10-P-6020SMG
    MODEL 230.470 with ENGINE 156.981 AR18.10-P-6020RMG
11 Remove oil pump chain (6)    
12 Remove vacuum reservoir (7) at cylinder crankcase upper section (11) On vehicles with vacuum reservoir (7) at cylinder crankcase upper section (11).  
13 Detach both engine supports (12)    
14 Loosen screw/bolts (14, 15) from cylinder crankcase lower section (13) in reverse order of tightening procedure Tightening procedure for crankcase bottom section AR03.20-P-4351-05AMG 
IMPORTANT Information on application of sealant to crankcase bottom section   AH01.40-P-1000-03AMG
    INSTALLATION IMPORTANT Lubricate the bearing shells and turn the crankshaft (5) to check that it moves freely.
INSTALLATION IMPORTANT Replace screw/bolts.		  
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection) *BA03.20-P-1001-01J 
    TORQUE SPECIFICATION Cylinder crankcase lower part to cylinder crankcase upper part *BA03.20-P-1002-01J 
    Loctite 5970 sealant *BR00.45-Z-1013-01A 
    SPECIAL TOOL Application gun Fig 3
15 Place match marks for connecting rod (1) and connecting rod bearing cap (2) (arrow) IMPORTANT The connecting rods (1) are cracked during production. The connecting rod bearing caps (2) are not interchangeable and cannot be fitted laterally reversed.  
16 Remove connecting rod bearing cap (2) Install and gauge connecting rod bearings AR03.10-P-6111-06VA
    Tighten connecting rod bolts
NOTES
Connecting rod bolts must  be replaced. The previously installed connecting rod bolts must not be installed again.
This is because for reusing loosening can occur and associated engine damage can occur.
IMPORTANT Assign connecting rod bearing cap (2) and lower connecting rod bearing shells (3) to each other. Mark connecting rod (1) and upper connecting rod bearing shells (4) relative to each other. While rotating the crankshaft (5) ensure that connecting rods (1) do not tilt.
INSTALLATION IMPORTANT Lubricate the bearing shells and turn the crankshaft (5) to check that it moves freely.
INSTALLATION IMPORTANT Install and measure connecting rod bearings.
INSTALLATION IMPORTANT Tighten connecting rod bolts according to tightening specification.		 AR03.10-P-6111-02AMG
    Connecting rod bearing play *BE03.20-P-1002-04E 
    TORQUE SPECIFICATION Connecting rod bearing cap on connecting rod *BA03.10-P-1001-01Q 
17 Remove rear crankshaft radial sealing ring   AR03.20-P-3063-01AMG
    IMPORTANT The installation takes place before mounting flywheel/drive plate.  
    SPECIAL TOOL Installation tool Fig 4
18 Remove crankshaft (5) from cylinder crankcase upper section (11)   AR03.20-P-4341-01AMG
    IMPORTANT Take out upper crankshaft-bearing shells (8) and thrust plates (9) from cylinder crankcase upper section (11). Mark thrust plates (9) relative to crankshaft fitted bearing. Note bearing play.
INSTALLATION IMPORTANT Check upper crankshaft bearing shells (8) and bottom crankshaft bearing shell (10) for wear.		  
    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 
    Main bearing shells standard dimension for crankcase and bearing cap Ø 67.950/67.966 mm *BE03.20-P-1002-03J 
    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 bearing cap Ø 67.950/67.966 mm *BE03.20-P-1004-03J 
    Crankshaft journal dia. *BE03.20-P-1001-02I 
    Crankshaft journal width at fit bearing *BE03.20-P-1002-02I 
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection) *BA03.20-P-1001-01J 
    TORQUE SPECIFICATION Cylinder crankcase lower part to cylinder crankcase upper part *BA03.20-P-1002-01J 
CLEAN Clean     
19 Remove sealant   AR01.00-P-0050-01A
    NOTES
Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces will be damaged otherwise.		  
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 cleaning spray (150 ml) *BR00.45-Z-1046-04A 
20 Install in the reverse order    
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
21 Perform an engine test run and check engine for leaktightness    
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
CONNECTING ROD

Number Designation ENGINE 156
BA03.10-P-1001-01Q Connecting rod bearing cap on connecting rod Stage 1 Nm 10
Stage 2 Nm 40
Stage 3 ∠° 90
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 loosen
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 loosen
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
Fig 3: Identifying Application Gun (112 589 00 25 00)
G09974124Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Installation Tool (111 589 08 43 00)
G09974125Courtesy 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-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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