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Install/gauge crankshaft bearings - AR03.20-P-4341-01AMG

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ENGINE 156, 159 

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
14.9.12 Crankcase housing lower part to cylinder crankcase cover   BA03.20-P-1002-01J
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation ENGINE 156 ENGINE 159
BE03.20-P-1001-04E Main bearing play Radial measurement when new mm 0, 022...0, 041 0, 020...0, 042
Axial measurement when new mm 0, 15...0, 316 0, 15...0, 316
CHECK VALUES OF CRANKSHAFT

Number Designation ENGINE 156 ENGINE 159
BE03.20-P-1001-02I Crankshaft journal dia. Nominal dia. mm 67, 950...67, 965 67, 950...67, 965
Repair stage 1 Blue (B) mm 67, 962...67, 965 67, 962...67, 965
Repair stage 2 Yellow (y) mm 67, 958...67, 962 67, 958...67, 962
Repair stage 3 Red (R) mm 67, 954...67, 958 67, 954...67, 958
Repair stage 4 Green (g) mm 67, 950...67, 954 67, 950...67, 954
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156 ENGINE 159
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 59
Bearing shell thickness mm 2, 267...2, 271 2, 277...2, 281
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156 ENGINE 159
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 54
Bearing shell thickness mm 2, 259...2, 263 2, 269...2, 273
CHECK VALUES OF CRANKSHAFT

Number Designation ENGINE 156 ENGINE 159
BE03.20-P-1002-02I Crankshaft journal width at fit bearing Marking N/0 mm 27, 900...29, 933 27, 900...29, 933
Marking N1/1 mm 28, 000...28, 033 -
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156 ENGINE 159
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 56
Bearing shell thickness mm 2, 263...2, 267 2, 273...2, 277
CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS

Number Designation ENGINE 156 ENGINE 159
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 52
Bearing shell thickness mm 2, 255...2, 259 2, 265...2, 269
CRANKSHAFT BEARING CAP

Number Designation ENGINE 159
BA03.20-P-1002-01L Cylinder crankcase lower section to cylinder crankcase upper section M6X40 Stage 1 Nm 4
Stage 2 ∠° 90
M8X25 Stage 1 Nm 10
Stage 2 ∠° 90
M8X50 Stage 1 Nm 10
Stage 2 ∠° 90
M8X65 Stage 1 Nm 10
Stage 2 ∠° 180
CRANKSHAFT BEARING CAP

Number Designation ENGINE 159
BA03.20-P-1001-01L Crankshaft bearing cap bolt (lower section of cylinder crankcase/main bearing threaded connection) M9 Stage 1 Nm 20
Stage 2 Nm 32
Stage 3 ∠° 90
Stage 4 ∠° 90
M10 Stage 1 Nm 20
Stage 2 Nm 40
Stage 3 ∠° 90
Stage 4 ∠° 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
  1. Blow out oil ducts with compressed air.
  2. Clean bearing points in cylinder crankcase upper section, main bearing cap or cylinder crankcase lower section and main bearing journal on crankshaft with chamois leather.

    IMPORTANT If a bearing damage has occurred, it may be necessary to remove any swarf from the connecting rod bores, oil ducts on the crankshaft as well as the cylinder crankcase. Do not use any hard objects for cleaning.

    IMPORTANT Assignment of the upper bearing shell halves to the basic journal of the crankshaft occurs via color markings on the rear side of the upper bearing shell halves and numbers on the upper cylinder crankcase (see Fig 1).

    Only the assigned letter and number combinations should be fitted together.

    Fig 1: Cylinder Crankcase Lower Section
    G10240658Courtesy of MERCEDES-BENZ USA

    Example: assignment of the upper bearing shells halves 

    IMPORTANT Assignment of the upper bearing shell halves takes place from the power take-off to the control side of the engine.

    Fig 2: Cylinder Crankcase Upper And Lower Section
    G10240659Courtesy of MERCEDES-BENZ USA
    • First number "1": A bearing shell halve with the color coding blue must be inserted in the bearing cap '1'.
    • Second number "2": A bearing shell halve with the color coding yellow must be inserted in the bearing cap '2'.
    • Third number "2": A bearing shell halve with the color coding yellow must be inserted in the bearing cap '3'.
    • Fourth number "2": A bearing shell halve with the color coding yellow must be inserted in the bearing cap '4'.
    • Fifth number "1": A bearing shell halve with the color coding blue must be inserted in the bearing cap '5'.

    IMPORTANT The bottom halves of the bearing shells (15) are assigned to the basic journal of the crankshaft by means of the first letter of the respective color.

    The color coding of the bottom halves of the bearing shells is located at the rear of the lower bearing shell halves.

    The initial letters of the particular colors are engraved on the journal of the crankshaft (15). When installing the lower bearing shell halves the order of the colors engraved on the journal of the crankshaft (15) must be observed.

    Example: Assignment of the upper bearing shells halves 

    • Y = YELLOW
    • R = RED
    • Y = YELLOW
    • R = RED
    • Y = YELLOW
      Fig 3: Cylinder Crankcase Upper Section, Crankshaft And Intermediate Gear Bearing Sleeve
      G10240660Courtesy of MERCEDES-BENZ USA
  3. Insert upper bearing shell halves (1) with the oil holes (2) and the oil grooves (3) in the cylinder crankcase upper section (7).

    IMPORTANT Ensure that the anti-twist locks (4) on the upper crankshaft bearing shell halves (1) are seated in the cutouts of the cylinder crankcase upper section (7).

  4. Insert lower bearing shell halves into bearing cap or cylinder crankcase lower section (8).

    IMPORTANT Ensure that the anti-twist locks on the lower bearing shell halves are seated in the recesses for the bearing cap or the cylinder crankcase lower section (8).

    Fig 4: Cylinder Crankcase Upper Section, Upper Bearing Shell Halves, Oil Holes And Oil Grooves
    G10240661Courtesy of MERCEDES-BENZ USA
  5. Insert crankcase (15) into cylinder crankcase upper section (7).
  6. Install upper thrust plates.

    IMPORTANT The oil grooves on the thrust plates must point to the crank webs.

    1. (7.1)  ENGINE 156

      Install bearing caps according to their markings.

      IMPORTANT When installing the fitted bearing cap firmly hold both thrust plates. The anti-twist locks of the thrust plates must sit in the grooves of the fitted bearing cap. The oil grooves of the thrust plate must point towards the crank webs.

    2. (7.2)  ENGINE 159

      Install cylinder crankcase lower section (8).

      IMPORTANT When installing cylinder crankcase lower section (8), hold both thrust plates. The anti-twist locks of the thrust plates must sit in the grooves. The oil grooves of the thrust plate must point towards the crank webs.

  8. Moisten screw/bolts on bearing cap or cylinder crankcase bottom section (8) on thread and bolt head contact surface with oil.
  9. Tighten screw/bolts according to tightening procedure.

    IMPORTANT Observe torque and tightening angle of screw/bolts.

  10. Turn crankshaft (15) to check for unobstructed movement.
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