Measure crankshaft and remount in bearings · ar0320w4355a · Mercedes-Benz WIS

AR03.20-W-4355A

Measure crankshaft and remount in bearings

10.11.11

ENGINES 541.9 in MODEL 950, 952, 953, 954

ENGINES 542.9 in MODEL 950, 952, 954

Measure crankshaft and remount in bearings

W03.20-0030-09

1 Crankshaft

2  Drop hardness tester

3  Micrometer

4 Main bearing caps

5 Central main bearing bolt

6 Side main bearing bolt

A Main bearing journal diameter

B Fitted bearing journal width

C Main bearing journal width

D Connecting rod bearing journal diameter

E Connecting rod journal width

F Fillet radii of main and connecting rod journals

G Crowning of main and connecting rod journal

H Main bearing inside diameter when installed

W03.20-0031-05

1 Crankshaft

7  Dial gage

8  Gauge stand

Modification notes

22.2.07	Connecting rod journal Ø connecting rod journal width, Ø standard width	Engine 541.9 EURO standardⅡ as of engine no. 098132 engine 541.9 EURO standard Ⅲ Engine 542.9 EURO standard II as of engine no. 098132 engine 542.9 EURO standard Ⅲ	*BE03.20-N-1004-02C
22.2.07	Fillet radius, main bearing journal	Engine 541.9 EURO standardⅡ as of engine no. 098132 engine 541.9 EURO standard Ⅲ Engine 542.9 EURO standard II as of engine no. 098132 engine 542.9 EURO standard Ⅲ	*BE03.20-N-1008-02C
22.2.07	Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)	Engine 541.9 EURO standardⅡ as of engine no. 098132 engine 541.9 EURO standard Ⅲ Engine 542.9 EURO standard II as of engine no. 098132 engine 542.9 EURO standard Ⅲ	*BE03.20-N-1009-02C
22.2.07	Crankcase main bearing inside Ø in installed condition, standard	Engine 541.9 EURO standardⅡ as of engine no. 098132 engine 541.9 EURO standard Ⅲ Engine 542.9 EURO standard II as of engine no. 098132 engine 542.9 EURO standard Ⅲ	*BE03.20-N-1012-02C

	Checking
1	Remove crankshaft		AR03.20-W-4351B
2	Clean crankshaft
3	Check front crankshaft flange for wear	 If worn or galled by radial sealing ring, a bearing race must be mounted on crankshaft flange.	AR03.20-W-2570A
4	Check connecting rod bearing shells and connecting rod bearing journals of crankshaft for wear	 If wear or grooves present 	AH03.10-N-0001-03A
		Replace or machine crankshaft.
5	Check main bearing shells and main bearing journals of crankshaft for wear	 If wear or grooves present 	AH03.20-N-1000-02A
		Replace or machine crankshaft.
6	Inspect main and conrod bearing journals for damage and cracks	 If damage or cracks present 
		Install new crankshaft.
7	Inspect hardness of main and connecting rod bearing journals with drop hardness tester (2)	 The bearing journal to be tested must be placed on a base for the test. The hardness must be achieved over at least two thirds of the circumference of the bearing journal.	*BE03.20-N-1009-02C
			*000589202100
		 If the specified hardness is not achieved 	*BE03.20-N-1009-02C
		Re-harden or replace crankshaft.
	Measure
8	Measure concentricity deviation of crankshaft (1)	 Engine 541.9 only. Measured at two middle main bearing journals, mounted at outer main bearing journals.	*BE03.20-N-1007-02C
		 Engine 542.9 only. Measured at the middle main bearing journal, mounted at the outer main bearing journals.	*BE03.20-N-1007-02C
9	Measure main and connecting rod bearing journals	Measure main bearing journal diameter (A) with the micrometer at two points (offset 90°).	*BE03.20-N-1001-02C
		Outside micrometer
		Main bearing journal width (C).	*BE03.20-N-1001-02C
		Fit bearing journal width (B).	*BE03.20-N-1002-02C
		Measure connecting rod bearing journal diameter (D) with micrometer at two points (offset approx. 90°).	*BE03.20-N-1004-02C
		Outside micrometer
		Fit bearing journal width (E).	*BE03.20-N-1004-02C
		Fillet radii (F) of main and connecting rod bearing journals.	*BE03.20-N-1008-02C
		Convexity (G) of main and connecting rod bearing journals.	*BE03.20-N-1010-02C
		 If damage and wear present, machine crankshaft to next undersize.
		Counterweights must be removed before machining the crankshaft (1) and recentered after being fitted on again.
	Mounting
10	Mount crankshaft (1) radially in bearings		AR03.20-W-4355-01A
		Main bearing journal diameter (A).	*BE03.20-N-1001-02C
		Crankshaft main bearing inner diameter (H) when installed.	*BE03.20-N-1012-02C
		 Pay attention to tightening sequence. First tighten central main bearing bolts (5) fully and then the side main bearing bolts (6).
		 Central main bearing bolts (5).	*BA01.40-N-1013-01D
		 Side main bearing bolts (6).	*BA01.40-N-1016-01D
			*001589532100
		 Quick calipers for internal measurements, company Hahn und Kolb D-70469 Stuttgart, Germany
		Outside micrometer
11	Install crankshaft (1)		AR03.20-W-4351B

Check values of crankshaft

Number	Designation			Engine 541.9 EURO standard Ⅱ up to engine no. 098131	Engine 542.9 EURO standardⅡ up to engine no. 098131


BE03.20-N-1001-02C	Main bearing journal dia., main bearing journal width (except main bearing fitted bearing journal)	Standard dia. Width	mm mm	107.980 - 108.000 42.000 - 42.160	107.980 - 108.000 42.000 - 42.160
		Dia. deviation 0.10 Width	mm mm	107.880 - 107.900 42.000 - 42.160	107.880 - 107.900 42.000 - 42.160
		Dia. deviation 0.25 Width	mm mm	107.730 - 107.750 42.000 - 42.160	107.730 - 107.750 42.000 - 42.160
		Dia. deviation 0.50 Width	mm mm	107.480 - 107.500 42.000 - 42.160	107.480 - 107.500 42.000 - 42.160
		Dia. deviation 0.75 Width	mm mm	107.230 - 107.250 42.000 - 42.160	107.230 - 107.250 42.000 - 42.160
		Dia. deviation 1.00 Width	mm mm	106.98 - 107.000 42.000 - 42.160	106.98 - 107.000 42.000 - 42.160
BE03.20-N-1002-02C	Main bearing journal dia. Fitted bearing journal width	Dia. standard width standard	mm mm	107.980 to 108.000 42.000 to 42.062	107.980 to 108.000 42.000 to 42.062
		Dia. deviation 0.10 width standard	mm mm	107.880 to 107.900 42.000 to 42.062	107.880 to 107.900 42.000 to 42.062
		Dia. deviation 0.25 width deviation 0.50	mm mm	107.730 to 107.750 42.500 to 42.562	107.730 to 107.750 42.500 to 42.562
		Dia. deviation 0.50 width deviation 0.50	mm mm	107.480 to 107.500 42.500 to 42.562	107.480 to 107.500 42.500 to 42.562
		Dia. deviation 0.75 width deviation 1.00	mm mm	107.230 to 107.250 43.000 to 43.062	107.230 to 107.250 43.000 to 43.062
		Dia. deviation 1.00 width deviation 1.00	mm mm	106.98 to 107.000 43.000 to 43.062	106.98 to 107.000 43.000 to 43.062
BE03.20-N-1004-02C	Connecting rod journal diameter, connecting rod journal width	Standard dia. Width	mm mm	93.980 - 94.000 37.000 - 37.100	93.980 - 94.000 81.000 - 81.140
		Dia. deviation 0.10 Width	mm mm	93.880 - 93.900 37.000 - 37.100	93.880 - 93.900 81.000 - 81.140
		Dia. deviation 0.25 Width	mm mm	93.730 - 93.750 37.000 - 37.100	93.730 - 93.750 81.000 - 81.140
		Dia. deviation 0.50 Width	mm mm	93.480 - 93.500 37.000 - 37.100	93.480 - 93.500 81.000 - 81.140
		Dia. deviation 0.75 Width	mm mm	93.230 - 93.250 37.000 - 37.100	93.230 - 93.250 81.000 - 81.140
		Dia. deviation 1.00 Width	mm mm	92.980 - 93.000 37.000 - 37.100	92.980 - 93.000 81.000 - 81.140
BE03.20-N-1006-02C	Main bearing axial play		mm	0.150 to 0.351	0.150 to 0.351
BE03.20-N-1007-02C	Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)		mm	0.06	0.06
BE03.20-N-1008-02C	Fillet radii	Main bearing journals	mm	3.5 to 4.0	3.5 to 4.0
		Connecting rod bearing journals	mm	3.5 to 4.0	3.5 to 4.0
BE03.20-N-1009-02C	Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)		HRC	53 to 59	53 to 59
BE03.20-N-1010-02C	Spherical shape	Main bearing journals	mm	0.002 (0.002)	0.002 (0.002)
		Connecting rod bearing journals	mm	0.002 (0.002)	0.002 (0.002)
BE03.20-N-1012-02C	Crankshaft main bearing inner dia. when installed	Default	mm	108.056 to 108.102	108.056 to 108.102
		Deviation 0.10	mm	107.956 to 108.002	107.956 to 108.002
		Deviation 0.25	mm	107.806 to 107.852	107.806 to 107.852
		Deviation 0.50	mm	107.556 to 107.602	107.556 to 107.602
		Deviation 0.75	mm	107.306 to 107.352	107.306 to 107.352
		Deviation 1.00	mm	107.056 to 107.102	107.056 to 107.102

Check values of crankshaft

Number	Designation			Engine 541.9 EURO standardⅡ as of engine no. 098132 Engine 541.9 EURO standard Ⅲ	Engine 542.9 EURO II standard as of engine no. 098132 Engine 542.9 EURO standard Ⅲ


BE03.20-N-1001-02C	Main bearing journal dia., main bearing journal width (except main bearing fitted bearing journal)	Standard dia. Width	mm mm	107.980 - 108.000 42.000 - 42.160	107.980 - 108.000 42.000 - 42.160
		Dia. deviation 0.10 Width	mm mm	107.880 - 107.900 42.000 - 42.160	107.880 - 107.900 42.000 - 42.160
		Dia. deviation 0.25 Width	mm mm	107.730 - 107.750 42.500 - 42.660	107.730 - 107.750 42.500 - 42.660
		Dia. deviation 0.50 Width	mm mm	107.480 - 107.500 42.500 - 42.660	107.480 - 107.500 42.500 - 42.660
		Dia. deviation 0.75 Width	mm mm	107.230 - 107.250 43.000 - 43.160	107.230 - 107.250 43.000 - 43.160
		Dia. deviation 1.00 Width	mm mm	106.980 - 107.000 43.000 - 43.160	106.980 - 107.000 43.000 - 43.160
BE03.20-N-1002-02C	Main bearing journal dia. Fitted bearing journal width	Dia. standard width standard	mm mm	107.980 to 108.000 42.000 to 42.062	107.980 to 108.000 42.000 to 42.062
		Dia. deviation 0.10 width standard	mm mm	107.880 to 107.900 42.000 to 42.062	107.880 to 107.900 42.000 to 42.062
		Dia. deviation 0.25 width deviation 0.50	mm mm	107.730 to 107.750 42.500 to 42.562	107.730 to 107.750 42.500 to 42.562
		Dia. deviation 0.50 width deviation 0.50	mm mm	107.480 to 107.500 42.500 to 42.562	107.480 to 107.500 42.500 to 42.562
		Dia. deviation 0.75 width deviation 1.00	mm mm	107.230 to 107.250 43.000 to 43.062	107.230 to 107.250 43.000 to 43.062
		Dia. deviation 1.00 width deviation 1.00	mm mm	106.98 to 107.000 43.000 to 43.062	106.98 to 107.000 43.000 to 43.062
BE03.20-N-1004-02C	Connecting rod journal diameter, connecting rod journal width	Standard dia. Width	mm mm	93.980 - 94.000 37.000 - 37.130	93.980 - 94.000 81.000 - 81.140
		Dia. deviation 0.10 Width	mm mm	93.880 - 93.900 37.000 - 37.130	93.880 - 93.900 81.000 - 81.140
		Dia. deviation 0.25 Width	mm mm	93.730 - 93.750 37.000 - 37.330	93.730 - 93.750 81.000 - 81.340
		Dia. deviation 0.50 Width	mm mm	93.480 - 93.500 37.000 - 37.330	93.480 - 93.500 81.000 - 81.340
		Dia. deviation 0.75 Width	mm mm	93.230 - 93.250 37.000 - 37.330	93.230 - 93.250 81.000 - 81.340
		Dia. deviation 1.00 Width	mm mm	92.980 - 93.000 37.000 - 37.330	92.980 - 93.000 81.000 - 81.340
BE03.20-N-1006-02C	Main bearing axial play		mm	0.150 to 0.351	0.150 to 0.351
BE03.20-N-1007-02C	Variation in concentricity measured at middle main bearing journal (mounted at outer main bearing journals)		mm	0.04	0.06
BE03.20-N-1008-02C	Fillet radii	Main bearing journals	mm	3.50 to 4.45	3.50 to 4.45
		Connecting rod bearing journals	mm	3.50 to 4.00	4.60 to 5.10
BE03.20-N-1009-02C	Hardness of main bearing and connecting rod bearing journals (Rockwell hardness)		HRC	51 to 61	51 to 61
BE03.20-N-1010-02C	Spherical shape	Main bearing journals	mm	0.002 (0.002)	0.002 (0.002)
		Connecting rod bearing journals	mm	0.002 (0.002)	0.002 (0.002)
BE03.20-N-1012-02C	Crankshaft main bearing inner dia. when installed	Default	mm	108.069 to 108.118	108.069 to 108.118
		Deviation 0.10	mm	107.969 to 108.018	107.969 to 108.018
		Deviation 0.25	mm	107.819 to 107.869	107.819 to 107.869
		Deviation 0.50	mm	107.569 to 107.618	107.569 to 107.618
		Deviation 0.75	mm	107.319 to 107.369	107.319 to 107.369
		Deviation 1.00	mm	107.069 to 107.118	107.069 to 107.118

 Cylinder crankcase, timing case cover, end cover

Number	Designation			Engine 541.9. 542.9


BA01.40-N-1013-01D	Central bolt, main bearing cap to crankcase	Stage 1	Nm	320
		Stage 2	°	90
BA01.40-N-1016-01D	Side bolt, main bearing cap to crankcase	Stage 1	Nm	120
		Stage 2	°	90

001 589 53 21 00

Dial indicator

Hardness tester

000 589 20 21 00

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