Remove/install crankshaft

AR03.20-P-4351OLI

Remove/install crankshaft

06.03.2020

Engine

654 in model 205, 253

Modification notes

31.01.2020

Bolt, connecting rod bearing cap to connecting rod

BA03.10-P-1001-01Y

1

Crankcase

2

Crankshaft

3

Bearing shells

4

Bearing pedestal

6

Crankshaft bearing cap

7

Bolts

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1

Remove timing case cover.

AR01.40-P-8000OLI

2

Remove end cover with front radial shaft sealing ring.

AR01.40-P-8922OLI

3.1

Remove crankcase lower section.

Engine 654 in model 205
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.40-P-3200OLI

3.2

Remove oil pan.

Engine 654 in model 205
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 654 in model 253

AR01.45-P-7500OLL

4

Determine and note down crankshaft main bearing end play.

AR03.20-P-4355-02CD

Crankshaft bearing clearance (when new)

*BE03.20-P-1001-04A

 Bolt, crankshaft bearing cap

*BA03.20-P-1001-01K

 Dial indicator holder

*363589022100

 Dial gage

*001589532100

5

Remove balance shafts with crankshaft bearing caps.

AR03.20-P-0020OLI

6

Place match marks on the connecting rods and the connecting rod bearing caps respectively on one side.


Do not mix up the connecting rod bearing caps.
Engine damage can occur otherwise.

7

Remove the connecting rod bolts and connecting rod bearing cap.


The connecting rods and the connecting rod bearing caps are cracked (broken). Do not mix up connecting rods.
Engine damage can occur otherwise.

8

Mark the connecting rod bearing shells relative to the associated connecting rod and connecting rod bearing cap.


Do not mix up the connecting rod bearing shells.
Engine damage can occur otherwise.

9

Remove the connecting rod bearing shells.

10

Mark crankshaft bearing caps (6) relative to crankcase (1).


Crankshaft bearing caps (6) and crankcase (1) are produced together. Do not interchange.
Engine damage can occur otherwise.

11

Remove screws (7) in reverse order of the tightening procedure.

Tightening procedure for crankshaft bearing caps

AR03.20-P-4351-02OLC

12

Remove crankshaft bearing caps (6).

13

Mark lower bearing shells (3) relative to respective crankshaft bearing cap (6).

Only where lower bearing shells (3) are reused.

14

Remove lower bearing shells (3) from crankshaft bearing caps (6).

15

Remove crankshaft (2) from the crankcase (1).

16

Mark upper bearing shells (3) and upper bearing pedestal (4) relative to crankcase (1).

Only where upper bearing shells (3) and upper bearing pedestal (4) are reused.

17

Remove upper bearing shells (3) and upper bearing pedestal (4) from crankcase (1).

18

Clean all parts of the crank assembly.


The parts of the crank assembly must be absolutely free of soiling.
Engine damage will occur otherwise.

 In the event of damage to the bearings, remove all chippings from the oil duct, the connecting rod bores, and the oil ducts of the crankshaft (2) and the crankcase (1).

Assembly cleaner

*BR00.45-Z-1028-04A



Check

19

Check connecting rods for blue discoloration, transverse scoring, and notches.

If problems exist,



Replace corresponding connecting rods.

AR03.10-P-7021OLI

20

Check bearing shells (3), bearing pedestals (4) and crankshaft bearing journals for wear and damage.

Information on assessing wear of main bearings and main bearing journals

AH03.20-P-1000-02MM

If problems exist,



Replace corresponding components.

21

Check connecting rod bearing shells and connecting rod journals for wear and damage.

Notes on assessing wear on connecting rod bearings and connecting rod journals

AH03.10-P-0001-03MM

If problems exist,



Replace corresponding components.



Install

22

Mount crankshaft (2) radially on bearings.

AR03.20-P-4355-01CD

 Commercially available devices/tools
Quick caliper for interior measurement

Bearing shells for crankcase and bearing cap

*BE03.20-P-1001-03N

Crankshaft journal Ø

*BE03.20-P-1001-02L

Crankshaft journal width at fit bearing

*BE03.20-P-1002-02L

 Bolt, crankshaft bearing cap

*BA03.20-P-1001-01K

 Dial gage

*001589532100

23

Assign new bearing shells (3) and new bearing pedestals(4).

Where bearing shells (3) and bearing pedestals (4) are replaced.

AR03.20-P-4360-01CD

24

Wet upper bearing shells (3) and upper bearing pedestal (4) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

25.1

Insert new upper bearing shells (3) and new upper bearing pedestal (4) in crankcase (1).

When replacing upper bearing shells (3) and upper bearing pedestal (4).

 Oil grooves in upper bearing shells (3) and in upper bearing pedestal (4) must point towards respective collar of crankshaft (2). Upper bearing shells (3) and upper bearing pedestal (4) have, in each case, a retaining lug as an anti-twist lock.

25.2

Insert previously marked upper bearing shells (3) and previously marked upper bearing pedestal (4) at respectively marked location in crankcase (1).

Where upper bearing shells (3) and upper bearing pedestal (4) are reused.

 Oil grooves in upper bearing shells (3) and in upper bearing pedestal (4) must point towards respective collar of crankshaft (2). Upper bearing shells (3) and upper bearing pedestal (4) have, in each case, a retaining lug as an anti-twist lock.

26

Wet crankshaft bearing journals and connecting rod journals with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

27

Position crankshaft (2) in the crankcase (1).

28

Wet lower bearing shells (3) and lower bearing pedestal (4) with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

29.1

Insert new lower bearing shells (3) and new lower bearing pedestal (4) in crankshaft bearing caps (6).

Where lower bearing shells (3) and lower bearing pedestal (4) are replaced.

 Oil grooves in lower bearing shells (3) and in lower bearing pedestal (4) must point towards respective collar of crankshaft (2). Lower bearing shells (3) and lower bearing pedestal (4) have, in each case, a retaining lug as an anti-twist lock.

29.2

Insert previously marked lower bearing shells (3) and previously marked lower bearing pedestal (4) into respectively marked crankshaft bearing cap (6).

Where lower bearing shells (3) and lower bearing pedestal (4) are reused.

 Oil grooves in lower bearing shells (3) and in lower bearing pedestal (4) must point towards respective collar of crankshaft (2). Lower bearing shells (3) and lower bearing pedestal (4) have, in each case, a retaining lug as an anti-twist lock.

30

Wet connecting rod bearing shells with engine oil.



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

31

Insert connecting rod bearing shells into the respectively marked connecting rod or respectively marked connecting rod bearing cap.


Insert connecting rod bearing shells in the connecting rods in a non-tilted manner.
The connecting rod can get damaged otherwise.

32

Insert connecting rod bearing caps and the associated connecting rod according to the applied markings on the crankshaft (2).


The connecting rods and the connecting rod bearing caps are cracked (broken). Do not mix up or install laterally reversed.
Otherwise the dimensional accuracy will no longer be obtained otherwise and can lead to engine damage.

33

Screw in new connecting rod bolts and tighten.

 Replace connecting rod bolts.

 Bolt, connecting rod bearing cap to connecting rod

*BA03.10-P-1001-01Y

34

Install balance shafts with crankshaft bearing caps.

AR03.20-P-0020OLI

 Do not tighten screws of crankshaft bearing caps at balance shafts.

35

Install crankshaft bearing caps (6) at respectively marked location in crankcase (1).

36

Tighten screws (7) of crankshaft bearing caps(6) and screws of crankshaft main bearings on balance shafts.

Tightening procedure for crankshaft bearing caps

AR03.20-P-4351-02OLC



Specified engine oils (service) - Overview

BB00.40-P-0223-02A

 Observe tightening procedure.

 Bolt, crankshaft bearing cap

*BA03.20-P-1001-01K

37.1

Install crankcase lower section.

Engine 654 in model 205
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.40-P-3200OLI

37.2

Install oil pan.

Engine 654 in model 205
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 654 in model 253

AR01.45-P-7500OLL

38

Install new end cover with front radial shaft sealing ring.

AR01.40-P-8922OLI

39

Install timing case cover.

AR01.40-P-8000OLI

Check values of crankshaft

Number

Designation

Engine 654

BE03.20-P-1001-02L

Crankshaft journal Ø

Nominal Ø

mm

54,940...54,965

Repair stage 1

Blue (B)

mm

54,960...54,965

2nd repair stage

Yellow (G)

mm

54,955...54,960

Repair stage 3

Red (R)

mm

54,950...54,955

Repair stage 4

White (W)

mm

54,945...54,950

Repair stage 5

Violet (V)

mm

54,940...54,945

Check values for crankshaft bearing shells

Number

Designation

Engine 654.916

Engine 654.920

BE03.20-P-1001-03N

Bearing shells for crankcase and bearing cap

Color code

blau

blau

Bearing shell thickness

Upper half of bearing bracket 1/2/3/5

mm

2,001…2,005

2,004...2,008

Lower half of bearing bracket 1/2/3/5

mm

2,001…2,006

2,004…2,009

Upper half of bearing block 4

mm

2,004…2,008

2,004…2,008

Lower half of bearing block 4

mm

2,004…2,009

2,004…2,009

Color code

gelb

gelb

Bearing shell thickness

Upper half of bearing bracket 1/2/3/5

mm

2,005…2,009

2,008…2,012

Lower half of bearing bracket 1/2/3/5

mm

2,006…2,011

2,009…2,014

Upper half of bearing block 4

mm

2,008…2,012

2,008…2,012

Lower half of bearing block 4

mm

2,009…2,014

2,009…2,014

Color code

rot

rot

Bearing shell thickness

Upper half of bearing bracket 1/2/3/5

mm

2,009…2,013

2,012…2,016

Lower half of bearing bracket 1/2/3/5

mm

2,011…2,016

2,014…2,019

Upper half of bearing block 4

mm

2,012…2,016

2,012…2,016

Lower half of bearing block 4

mm

2,014…2,019

2,014…2,019

Color code

weiß

weiß

Bearing shell thickness

Upper half of bearing bracket 1/2/3/5

mm

2,013…2,017

2,016…2,020

Lower half of bearing bracket 1/2/3/5

mm

2,016…2,021

2,019…2,024

Upper half of bearing block 4

mm

2,016…2,020

2,016…2,020

Lower half of bearing block 4

mm

2,019…2,024

2,019…2,024

Color code

violett

violett

Bearing shell thickness

Lower half of bearing bracket 1/2/3/5

mm

2,021…2,026

2,024…2,029

Lower half of bearing block 4

mm

2,024…2,029

2,024…2,029

Test specifications for crankshaft bearing clearance

Number

Designation

Engine 654

BE03.20-P-1001-04A

Crankshaft bearing clearance (when new)

Radial measurement when new

mm

0,027...0,048

Radial wear limit

mm

-

Axial measurement when new

mm

0,12...0,353

Axial wear limit

mm

-

Check values of crankshaft

Number

Designation

Engine 654

BE03.20-P-1002-02L

Crankshaft journal width at fit bearing

Marking N colorless (0)

mm

24,500...24,540

 Connecting rod

Number

Designation

Engine 654

BA03.10-P-1001-01Y

Bolt, connecting rod bearing cap to connecting rod

For initial tightening after cracking

Stage 1

Nm

5

Stage 2

Nm

25

Stage 3

°

180

Stage 4

Loosen bolts

Stage 5

Nm

5

Stage 6

Nm

25

Stage 7

°

90

For subsequent tightening

Stage 1

Nm

5

Stage 2

Nm

25

Stage 3

°

90

 Crankshaft bearing cap

Number

Designation

Engine 654

BA03.20-P-1001-01K

Bolt, crankshaft bearing cap

Stage 1

Nm

10

Stage 2

Nm

45

Stage 3

°

180

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01