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

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ENGINES 272, 273 in MODEL 212 

Shown on engine 272 without pulse wheel on camshaft adjusters 

Fig 1: Crankshaft Remove/Install Components (1 Of 2)
G09974134Courtesy of MERCEDES-BENZ USA
Fig 2: Crankshaft Remove/Install Components (2 Of 2)
G09974135Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

10.2.10 Value changed: side crankshaft bearing cap bolt, stage 1 Engine 272 *BA03.20-P-1002-01D 
  Value changed: side crankshaft bearing cap bolt, stage 2 Engine 272 *BA03.20-P-1002-01D 
REMOVING Removing     
IMPORTANT The ground line on the battery must always  be detached before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door or the trunk lid Model 212.057/257  
1 Drain engine oil    
  Engine oil and filter change   AP18.00-P-0101EW
2.1 Remove engine with transmission Vehicles without 4MATIC AR01.10-P-2401EW
2.2 Remove engine with front axle carrier Vehicles with 4MATIC AR01.10-P-2500EW
3 Detach engine from front axle carrier Vehicles with 4MATIC AR01.10-P-2510CWX
4 Detach transmission from engine With transmission 722.9 (except code 722.96)   AR27.10-P-0500EV
    With transmission 722.96 AR27.10-P-0500CWX
    With transmission 711.6 -
    With transmission 716.6 -
5 Mount engine onto assembly stand    
6 Remove front cover at left cylinder head   AR01.30-P-5700EWL
7 Remove right cylinder head cover (12) With engine 273, 272 (except 272.983) AR01.20-P-5012EL
    With engine 272.983 AR01.20-P-5012ELD
8 Rotate engine at crankshaft (7) in direction of rotation of engine to a 40° crank angle after ignition TDC and check basic position of camshaft   AR05.20-P-6010-01VB
9 Remove flywheel/drive plate   AR03.30-P-8001EW 
10 Detach oil pan Engine 273 with rear sump AR01.45-P-7500EW
    Engine 272 with rear sump AR01.45-P-7500EWD
    Engine 272, 273 with center sump AR01.45-P-7500EWX
11 Remove rear crankshaft radial sealing ring   AR03.20-P-3063EWS
12 Remove oil pump   AR18.10-P-6020EW
13 Remove oil baffle from cylinder crankcase   AR03.10-P-7021-01SX
14 Remove alternator   AR15.40-P-5032EW
15 Remove chain tensioner   AR05.10-P-7800EW
16 Remove timing case cover NOTES Remove timing case cover carefully. Damage can occur to the cylinder head gaskets otherwise. AR01.40-P-8000EWS
17 Remove oil pump chain (11)    
18 Remove camshaft adjuster (13) on right cylinder head Camshaft adjuster on exhaust camshafts AR05.20-P-7201EWA
    Camshaft adjuster on intake camshafts AR05.20-P-7201EWE
19 Detach timing chain drive gear (14) from crankshaft (7) IMPORTANT Secure key (15).  
20 Mark connecting rod (1) and connecting rod bearing cap (2) on one side relative to each other (arrow) IMPORTANT Connecting rod (1) and connecting rod bearing cap (2) are cracked. They must not be swapped or installed on wrong sides as the dimensional accuracy would no longer be given.  
21 Remove connecting rod bearing cap (2) and lower connecting rod bearing shells (3) IMPORTANT Mark connecting rod bearing cap (2) and lower connecting rod bearing shells (3) relative to each other. Mark connecting rods (1) and connecting rod bearing caps (4) relative to each other. While rotating crankshaft (7) ensure that connecting rods (1) do not get caught.  
22 Loosen crankshaft bearing cap (5) bolts and crankshaft fitted bearing cap (6) in reverse order of tightening procedure Engine 272 AR03.20-P-4351-02VA
    Engine 273 AR03.20-P-4351-02SX
23 Remove crankshaft bearing cap (5) and crankshaft fitted bearing cap (6) IMPORTANT Carefully pry out crankshaft bearing cap (5) and crankshaft fitted bearing cap (6). Mark lower crankshaft bearing shells (10) relative to the respective crankshaft bearing caps (5) and crankshaft fitted bearing caps (6). Mark lower thrust plate (9) relative to crankshaft fitted bearing cap (6).  
24 Remove crankshaft (7) from crankcase    
25 Take out upper crankshaft bearing shells (8) and upper thrust plates (9) from the crankcase IMPORTANT Mark upper crankshaft bearing shell (8) relative to respective crankshaft bearing and upper thrust plate (9) relative to crankshaft fitted bearing.  
INSTALLING Install     
26 Lubricate upper crankshaft bearing shells (8) and insert them into crankcase IMPORTANT When replacing the crankshaft bearing shells (8) or the crankshaft (7):
↓
Assign crankshaft bearing shells (8):		  
    Engine 272 AR03.20-P-4360-01VA 
    Test specifications for crankshaft bearing clearance *BE03.20-P-1001-04E 
    Engine 273 AR03.20-P-4360-01SX 
    Test specifications for crankshaft bearing clearance *BE03.20-P-1001-04E 
27 Lubricate crankshaft journals and insert crankshaft (7) in crankcase IMPORTANT Lubricate crankshaft journals.  
28 Lubricate upper thrust plates (9) without retaining lugs and insert them into crankshaft fitted bearing in crankcase IMPORTANT Oil grooves in upper thrust plates (9) must point toward thrust collars of crankshaft (7).  
29 Lubricate lower crankshaft bearing shells (10) and lower thrust plates (9) with retaining lugs and insert them into crankshaft bearing cap (5) and into crankshaft fitted bearing cap (6) IMPORTANT When replacing the crankshaft bearing shells (10) or the crankshaft (7):
↓
Assign crankshaft bearing shells (10):		  
    Engine 272 AR03.20-P-4360-01VA 
    Test specifications for crankshaft bearing clearance *BE03.20-P-1001-04E 
    Engine 273 AR03.20-P-4360-01SX 
    Test specifications for crankshaft bearing clearance *BE03.20-P-1001-04E 
30 Insert crankshaft bearing cap (5) and crankshaft fitted bearing cap (6) IMPORTANT The crankshaft bearing cap (5) and fitted bearing cap (6) are numbered consecutively. Pay attention to fit:
↓
Fit for crankshaft bearing cap (5) or crankshaft fitted bearing cap (6)		  
IMPORTANT   Engine 272 AH03.20-P-4351-02VA
IMPORTANT   Engine 273 AH03.20-P-4351-02SX
31 Insert and tighten bolts for crankshaft bearing caps (5) and for crankshaft fitted bearing cap (6) NOTES Bolts must be replaced with new ones, otherwise there is risk of breakage. Tighten bolts according to tightening scheme:
↓
Tightening procedure for crankshaft bearing cap (5) or crankshaft fitted bearing cap (6)		  
    Engine 272 AR03.20-P-4351-02VA
    Engine 273 AR03.20-P-4351-02SX
    TORQUE SPECIFICATION *BA03.20-P-1001-01D 
    TORQUE SPECIFICATION *BA03.20-P-1002-01D 
    TORQUE SPECIFICATION *BA03.20-P-1003-01D 
32 Rotate crankshaft (7) and check for unobstructed movement    
33 Determine crankshaft bearing axial play Engine 272 AR03.20-P-4291-03VA
    Engine 273 AR03.20-P-4291-03SX
    SPECIAL TOOL Dial indicator Figure
    SPECIAL TOOL Extension Fig 4
    SPECIAL TOOL Gage stand Figure
    Test value for main bearing play *BE03.20-P-1001-04E 
34 Check connecting rod bolts   AR03.10-P-6111-01VA
    Test specifications for connecting rod bolts *BE03.10-P-1001-03A 
35 Mount connecting rod bearing and check play Engine 272 AR03.10-P-6111-06VA
    Engine 273 AR03.10-P-6111-08SX
    Test specifications for connecting rod bearing play *BE03.20-P-1002-04E 
36 Tighten connecting rod bolts   AR03.10-P-6111-02VA
    TORQUE SPECIFICATION *BA03.10-P-1001-01E 
37 Rotate crankshaft (7) and check for unobstructed movement    
38 Slide timing chain drive gear (14) onto crankshaft (7) IMPORTANT Observe key (15).  
39.1 Install camshaft adjusters (13) for right cylinder head while setting basic positions of camshafts and balance shaft (16) Engine 272
IMPORTANT Check the engine timing and basic position of balance shaft (16) at 40° crank angle after ignition TDC. At 40° crank angle after ignition TDC, the key (15) aligns with marking (17) on the cylinder crankcase and notch (18) on balance shaft (16) aligns with marking (19).		  
    Camshaft adjuster on exhaust camshafts AR05.20-P-7201EWA
    Camshaft adjuster on intake camshafts AR05.20-P-7201EWE
39.2 Install camshaft adjuster (13) on right cylinder head while adjusting basic positions of camshaft Engine 273
IMPORTANT Check engine timing at a 40° crank angle after ignition TDC. At 40° crank angle after ignition TDC, fitting key (15) aligns with the marking (17) on the cylinder crankcase.		  
    Camshaft adjuster on exhaust camshafts AR05.20-P-7201EWA
    Camshaft adjuster on intake camshafts AR05.20-P-7201EWE
40 Place oil pump chain (11) on drive gear    
41 Install timing case cover   AR01.40-P-8000EWS
42 Install chain tensioner IMPORTANT Replace chain tensioner.
The previously installed chain tensioner must not be reinstalled because during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.		 AR05.10-P-7800EW
43 Mount oil baffle on cylinder crankcase   AR03.10-P-7021-01SX
    TORQUE SPECIFICATION *BA18.10-P-1006-01B 
44 Install oil pump   AR18.10-P-6020EW
45 Install rear crankshaft radial sealing ring NOTES Replace rear crankshaft radial sealing ring with new one to ensure that there are no leaks. AR03.20-P-3063EWS
46 Fit oil pan Engine 273 with rear sump AR01.45-P-7500EW
    Engine 272 with rear sump AR01.45-P-7500EWD
    Engine 272, 273 with center sump AR01.45-P-7500EWX
47 Install alternator   AR15.40-P-5032EW
48 Install right cylinder head cover (12) With engine 273, 272 (except 272.983) AR01.20-P-5012EL
    With engine 272.983 AR01.20-P-5012ELD
49 Install front cover on left cylinder head   AR01.30-P-5700EWL
50 Remove flywheel/drive plate   AR03.30-P-8001EW 
51 Detach engine from engine assembly stand    
52 Attach transmission to engine With transmission 722.9 (except code 722.96) AR27.10-P-0500EV
    With transmission 722.96 AR27.10-P-0500CWX
    With transmission 716.6 -
53 Fit engine on front axle carrier Vehicles with 4MATIC AR01.10-P-2510CWX
54.1 Install engine with front axle carrier Vehicles with 4MATIC AR01.10-P-2500EW
54.2 Install engine with transmission Vehicles without 4MATIC AR01.10-P-2401EW
55 Pour in engine oil    
  Engine oil and filter change   AP18.00-P-0101EW
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 272 Engine 273
BE03.20-P-1001-04E Main bearing play Radial measurement new mm 0.022 to 0.046 0.022 to 0.046
Axial measurement when new mm 0.100 to 0.266 0.100 to 0.266
BE03.20-P-1002-04E Connecting rod bearing play Radial measurement new mm 0.022...0.066 0.022...0.066
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation Engine 272 Engine 273
BE03.10-P-1001-03A Connecting rod bolts Thread diameter M 8X1 8X1
Shank length New mm 39.5 39.5
  max. mm 40.5 40.5
CRANKSHAFT BEARING CAP

Number Designation Engine 272 Engine 273
BA03.20-P-1001-01D Bolt for crankshaft bearing cap M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
BA03.20-P-1002-01D Side crankshaft bearing cap bolt M8 Stage 1 Nm 20 20
Stage 2 ∠° 90 90
BA03.20-P-1003-01D Bolt for crankshaft bearing cap M10 Stage 1 Nm 5 5
Stage 2 Nm 30 30
Stage 3 ∠° 90 90
CONNECTING ROD

Number Designation Engine 272 Engine 273
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 20 25
Stage 3 ∠° 90 90
OIL PUMP

Number Designation Engine 272 Engine 273
BA18.10-P-1006-01B Bolt, oil baffle to crankcase Nm 9 9
Fig 3: Identifying Dial Indicator (001 589 32 21 00)
G09974136Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Extension (366 589 00 21 05)
G09974137Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Dial Indicator Holder (363 589 02 21 00)
G09974138Courtesy of MERCEDES-BENZ USA
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