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

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ENGINE 152 in MODEL 172 

ENGINE 157 in MODEL 212, 218 

ENGINE 278 in MODEL 207, 212, 218 

Fig 1: Crankshaft Remove/Install Components
G09974129Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1 Remove engine with front axle carrier MODEL 172.4 with ENGINE 152.9 AR01.10-P-2500MMI
    MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.10-P-2500ELB
2 Detach transmission with torque converter MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.96 AR27.10-P-0500CWX
    MODEL 172 with ENGINE 152 with TRANSMISSION 722.9 AR27.10-P-0500W
    MODEL 212, 218 with ENGINE 157 with TRANSMISSION 722.931/971
MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500EV
3 Secure engine to assembly stand Passenger car engine assembly stand  
4 Remove oil pan MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.45-P-7500ELB
    MODEL 172.4 with ENGINE 152.9 AR01.45-P-7500MMI
5 Remove oil pump MODEL 172.4 with ENGINE 152.9 AR18.10-P-6020MMI
    MODEL 207 with ENGINE 278 AR18.10-P-6020FH
    MODEL 212, 218 with ENGINE 157, 278 AR18.10-P-6020EL
6 Remove rear crankshaft radial sealing ring MODEL 212, 218 with ENGINE 157, 278 AR03.20-P-3063EL
    MODEL 207 with ENGINE 278 AR03.20-P-3063FH
    MODEL 172.4 with ENGINE 152.9 AR03.20-P-3063W
7 Remove timing case cover MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.40-P-8000ELB
    MODEL 172.4 with ENGINE 152.9 AR01.40-P-8000MMI
    IMPORTANT Remove crankshaft radial sealing ring on timing case cover.  
8 Remove primary drive timing chain MODEL 172 with ENGINE 152 AR05.10-P-7612MMI
    MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR05.10-P-7612ELB
9 Detach timing chain drive gear (3) from crankshaft (6)    
10 Mark connecting rod and connecting rod bearing cap on one page relative to each other and to the respective cylinder    
11 Remove connecting rod bearing shells and mark relative to the associated connecting rods and connecting rod bearing caps if necessary    
12 Loosen screw/bolts for the crankshaft bearing cap (1) and the crankshaft fitted bearing cap (2) in reverse order of the tightening procedure Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02MM
13 Remove crankshaft bearing cap (1) and crankshaft fitted bearing cap (2) IMPORTANT Carefully pry out crankshaft bearing cap (1) and crankshaft fitted bearing cap (2). Mark lower crankshaft bearing shells (4) relative to the respective crankshaft bearing caps (1) and the crankshaft fitted bearing cap (2). Mark lower thrust plate (A) relative to the crankshaft fitted bearing cap (2).  
14 Remove crankshaft (6) from cylinder crankcase    
15 Take out upper crankshaft bearing shells (5) and upper thrust plates (B) from the cylinder crankcase IMPORTANT Mark upper crankshaft bearing shells (5) relative to the respective crankshaft bearing and upper thrust plates (B) relative to the crankshaft fitted bearing.  
CLEAN Clean     
16 Clean all power unit components NOTES The power unit components must be absolutely free of soiling.
Engine damage can occur otherwise.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
17 Check all power unit components and replace if necessary    
INSTALLING Install     
18 Assign crankshaft bearing shells (4, 5) if necessary and insert into cylinder crankcase    
      AR03.20-P-4360-01MM 
19 Insert crankshaft (6) in the cylinder crankcase and install crankshaft bearing cap (1) and crankshaft fitted bearing cap (2)   AR03.20-P-4360-01MM 
20 Insert and tighten screw/bolts for crankshaft bearing caps (1) and for crankshaft fitted bearing cap (2) Tightening procedure for crankshaft bearing caps
IMPORTANT Observe tightening procedure! Screw/bolts must be replaced.		 AR03.20-P-4351-02MM
    TORQUE SPECIFICATION Bolt, crankshaft bearing cap *BA03.20-P-1003-01D 
    TORQUE SPECIFICATION Side crankshaft bearing cap bolt *BA03.20-P-1002-01D 
    TORQUE SPECIFICATION Bolt for crankshaft bearing cap *BA03.20-P-1001-01D 
21 Rotate crankshaft (6) and check for unobstructed movement    
22 Determine crankshaft bearing axial play   AR03.20-P-4291-03MM
    Main bearing play *BE03.20-P-1001-04E 
    SPECIAL TOOL Dial indicator holder Fig 3
    SPECIAL TOOL Dial gage Fig 4
23 Check connecting rod bolts   AR03.10-P-6111-01MM
    Connecting rod bolts *BE03.10-P-1001-03A 
24 Mount connecting rod bearing   AR03.10-P-6111-06MM
25 Tighten connecting rod bolts   AR03.10-P-6111-02MM
    TORQUE SPECIFICATION
ENGINE 152 in MODEL 172		 *BA03.10-P-1001-01T 
    TORQUE SPECIFICATION
ENGINE 157 in MODEL 212, 218
ENGINE 278 in MODEL 207, 212, 218		 *BA03.10-P-1001-01E 
26 Rotate crankshaft (6) and check for unobstructed movement    
27 Slide timing chain drive gear (3) onto crankshaft (6) IMPORTANT Ensure correct seating of the fitted spring.  
28 Install primary drive timing chain MODEL 172 with ENGINE 152 AR05.10-P-7612MMI
    MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR05.10-P-7612ELB
29 Install timing case cover MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.40-P-8000ELB
    MODEL 172.4 with ENGINE 152.9 AR01.40-P-8000MMI
30 Install new front crankshaft radial seal   AR03.20-P-3000-01MM
    SPECIAL TOOL Sleeve Fig 5
31 Install new rear crankshaft radial sealing ring   AR03.20-P-3063-01MMB
    TORQUE SPECIFICATION Screw/bolt, oil pan to crankcase/timing case cover/rear end cover *BA01.45-P-1001-01E 
    TORQUE SPECIFICATION Bolt, rear end cover to crankcase *BA01.40-P-1002-01K 
    SPECIAL TOOL Insertion tool Fig 2
32 Install oil pump MODEL 172.4 with ENGINE 152.9 AR18.10-P-6020MMI
    MODEL 207 with ENGINE 278 AR18.10-P-6020FH
    MODEL 212, 218 with ENGINE 157, 278 AR18.10-P-6020EL
33 Install oil pan MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.45-P-7500ELB
    MODEL 172.4 with ENGINE 152.9 AR01.45-P-7500MMI
34 Detach engine from assembly stand    
35 Attach transmission with torque converter MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.96 AR27.10-P-0500CWX
    MODEL 172 with ENGINE 152 with TRANSMISSION 722.9 AR27.10-P-0500W
    MODEL 212, 218 with ENGINE 157 with TRANSMISSION 722.931/971
MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500EV
36 Install engine with front axle carrier MODEL 172.4 with ENGINE 152.9 AR01.10-P-2500MMI
    MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.10-P-2500ELB
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation ENGINE 152 ENGINE 157, 278
BE03.10-P-1001-03A Connecting rod bolts Thread Ø M 8X1 8X1
Shank length New mm 42, 5 42, 5
Max. mm 43, 3 43, 3
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation ENGINE 152 ENGINE 157
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 046 0, 022...0, 046
Axial measurement when new mm 0, 140...0, 280 0, 140...0, 280
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation ENGINE 278
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 046
Axial measurement when new mm 0, 140...0, 280
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number Designation ENGINE 157 ENGINE 278
BA01.40-P-1002-01K Bolt, rear end cover to crankcase Nm 9 9
CYLINDER CRANKCASE, TIMING CASE COVER, END COVER

Number Designation ENGINE 152
BA01.40-P-1002-01K Bolt, rear end cover to crankcase Nm 9
OIL PAN

Number Designation ENGINE 152 ENGINE 157
BA01.45-P-1001-01E Screw/bolt, oil pan to crankcase/timing case cover/rear end cover M6 Nm 11 9
OIL PAN

Number Designation ENGINE 278
BA01.45-P-1001-01E Screw/bolt, oil pan to crankcase/timing case cover/rear end cover M6 Nm 9
CONNECTING ROD

Number Designation ENGINE 157 ENGINE 278
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 25 25
Stage 3 ∠° 90 90
CONNECTING ROD

Number Designation Engine 152
BA03.10-P-1001-01T Connecting rod bolt Stage 1 Nm 40
Stage 2 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 152 ENGINE 157
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 278
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8 Stage 1 Nm 20
Stage 2 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 152 ENGINE 157
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 278
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Stage 1 Nm 20
Stage 2 ∠° 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 152 ENGINE 157
BA03.20-P-1003-01D Bolt, crankshaft bearing cap M10 Stage 1 Nm 5 5
Stage 2 Nm 30 30
Stage 3 ∠° 90 90
CRANKSHAFT BEARING CAP

Number Designation ENGINE 278
BA03.20-P-1003-01D Bolt, crankshaft bearing cap M10 Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 ∠° 90
Fig 2: Identifying Insertion Tool (273 589 00 43 00)
G09974130Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Dial Indicator Holder (363 589 02 21 00)
G09974131Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Dial Gauge (001 589 32 21 00)
G09974132Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Sleeve (119 589 01 14 00)
G09974133Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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