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

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ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221

Shown on engine 646.961

Fig 1: Crankshaft Remove/Install Components - Shown On Engine 646.961

Courtesy of MERCEDES-BENZ USA

Shown on engine 651.9

Fig 2: Crankshaft Remove/Install Components - Shown On Engine 651.9

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

8.11.10

Reference to remove crankshaft radial sealing ring, added
Reference to measure, mount crankshaft, added

Operation step 7
Step 15

	Remove/install
1	Secure vehicle on vehicle lift	Model 166	AR00.60-P-0100GZ
		Model 172	AR00.60-P-0100T
		Model 204, 207	AR00.60-P-0100CW
		Model 212, 218	AR00.60-P-0100EWS
		Model 221.0/1	AR00.60-P-0100SX
2	Remove timing case cover		AR01.40-P-8000CD
3	Remove oil pan	MODEL 166.0	AR01.45-P-7500GQA
		Model 172	AR01.45-P-7500SLK
		Model 204, 207, 212, 218 except 4MATIC	AR01.45-P-7500CD
		Model 204, 212 with 4MATIC	AR01.45-P-7500OMD
		Model 204.9 except 4MATIC	AR01.45-P-7500OND
		Model 221	AR01.45-P-7500SXA
4	Remove bracket together with poly-V belt tensioning device		AR13.25-P-3300CD
5	Remove bolts (6) at end cover (7)		*BA01.40-P-1002-01X
6	Remove end cover (7) on cylinder crankcase	Clean sealing surfaces on end cover (7) and on cylinder crankcase. Apply sealant according to sealant path. Pay attention to correct seating of fitting sleeves (8).
		Squeeze gun	Figure
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
		Loctite 7063 cleaning spray	*BR00.45-Z-1046-04A
	Information on application of sealant to end cover of crankcase		AH01.40-P-1000-04CD
7	Take out the crankshaft radial sealing ring (9) from the end cover (7)	Install crankshaft radial sealing ring (9) only after the end cover (7) has been installed.	AR03.20-P-3000CD
8	Mark connecting rods (5) in connecting rod bearing cap (4) on one side to each other for this step	Connecting rods (5) and connecting rod bearing caps (4) are cracked (broken). They must not be swapped over with each other or installed the wrong way round. The dimensional accuracy will no longer obtainable otherwise.
9	Remove connecting rod bearing cap (4)	While rotating the crankshaft (20) ensure that connecting rods (5) do not get jammed. Do not mix up top and bottom connecting rod bearing shells.
		Bolt connecting rod cap to connecting rod	*BA03.10-P-1001-01R
10	Remove intermediate gear for the engine control		AR05.10-P-7620CD
11	Remove Lanchester balancer		AR03.20-P-1100CD
12	Take crankshaft (20) out of crankcase
13	Mark the crankshaft bearing shells (21, 24) and thrust plates (22, 23) to one another
14	Remove crankshaft bearing shells (21, 24) and thrust plates (22, 23)	As of engine number 651 XXX XX 194 505, the crankcase axial bearings are installed on cylinder 4 instead of on cylinder 3. When renewing the crankshaft bearing shell (21, 24) or the crankshaft (20) the crankshaft bearing shells (21, 24) must be assigned. See: ↓
		Assign crankshaft bearing shells	AR03.20-P-4360-01CD
		Crankshaft bearing clearance (when new) Oil crankshaft bearing shells (21, 24) before inserting the crankshaft (20). The oil grooves in thrust plates (22, 23) must point towards the respective collar of the crankshaft (20). The thrust plates (22) in the bearing cap have each one retaining lug as an anti-twist lock:	*BE03.20-P-1001-04A
	Measure
15	Measure crankshaft (20), mount in bearings		AR03.20-P-4355CD
16	Check connecting rod bolts		AR03.10-P-6111-01T
		Connecting rod bolt	*BE03.10-P-1001-03I
17	Install in the reverse order
18	Connect STAR DIAGNOSIS, read out fault memory and erase if required	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.	AD00.00-P-2000-04A
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
19	Conduct engine test run and check engine for leaks

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number	Designation				Engine 651
BE03.10-P-1001-03I	Connecting rod bolt	Thread diameter		M	8X1
		Shank length	New	mm	47 (±0.3)
			max.	mm	48

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 651
BE03.20-P-1001-04A	Crankshaft bearing clearance (when new)	Radial measurement new	mm	0.028 to 0.063
		Radial wear limit	mm	-
		Axial measurement when new	mm	0.110 to 0.300
		Axial wear limit	mm	-

CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation		Engine 651
BA01.40-P-1002-01X	Firewall cover on cylinder crankcase	Nm	9

CONNECTING ROD

Number	Designation				Engine 651
BA03.10-P-1001-01R	Screw/bolt, connecting rod bearing cap to connecting rod	At initial tightening torque after cracking	Stage 1	Nm	5
			Stage 2	Nm	25
			Stage 3	∠°	180
		For subsequent tightening	Stage 1	Nm	5
			Stage 2	Nm	25
			Stage 3	∠°	90

Fig 3: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy 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-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10