Remove/install crankshaft · ar0320p4351cd · Mercedes-Benz WIS

AR03.20-P-4351CD

Remove/install crankshaft

06.03.2020

Engine

651 in model 166, 172, 204, 207, 212, 218, 221

Modification notes

27.04.2018	Document completely revised.
27.04.2018	Check bearing shells (3), thrust bearing shells (4), and crankshaft bearing journals for wear and damage, added.	Operation step 21
27.04.2018	Check connecting rod bearing shells (14) and connecting rod journals for wear and damage, added.	Operation step 22

1	Connecting rod bolts
2	Connecting rod bearing cap
3	Bearing shells
4	Fitted bearing shell
5	Balance shaft housing
10	Crankcase
12	Connecting rod
13	Crankshaft
14	Connecting rod bearing shells

P03.20-2474-06

P03.20-2299-07

Shown on engine 651.9

6	Bolts		8	Pilot bushing		9	Radial shaft sealing ring
7	End cover

 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 avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Remove
1	Remove timing case cover.		AR01.40-P-8000CD
2	Check basic position of camshafts.		AR05.20-P-6010CD
		If the basic position of the camshafts is incorrect,
		
		Set basic position of camshafts.
			AR05.20-P-6020CD
3	Check basic position of the balance shafts.		AR03.20-P-3637CD
		If the basic position of the balance shafts is incorrect,
		
		Set basic position of the balance shaft.
			AR03.20-P-3638CD
4	Remove oil pan.	Engine 651 in model 166	AR01.45-P-7500GQA
		Engine 651 in model 172	AR01.45-P-7500SLK
		Engine 651 in model 204 (except 204.9), 212 with transmission 711.6 except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 204 (except 204.9), 212 with transmission 722 except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 207 with transmission 711.6 Engine 651 in model 207, 218 with transmission 722 Engine 651 in model 212 with transmission 724.20 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500CD
		Engine 651 in model 204, 212 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500OMD
		Engine 651 in model 204.9 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500OND
		Engine 651 in model 221	AR01.45-P-7500SXA
5	Remove carrier with clamping device for poly-V-belt.	Engine 651 in model 166, 172, 204, 207, 212, 218, 221
		Engine 651 in model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221	AR13.25-P-3300CD
6	Remove screws (6) from end cover (7).
7	Remove end cover (7) from crankcase (10).
8	Remove radial shaft sealing ring (9) from the end cover (7).		AR03.20-P-3000CD
9	Loosen connecting rod bolts (1) of the connecting rod bearing caps (2).	 External Torx set	*001589760900
10	Remove intermediate gears of the engine timing.		AR05.10-P-7620CD
11	Remove balance shaft housing (5).		AR03.20-P-1100CD
12	Place match marks on the connecting rods (12) and the connecting rod bearing caps (2) respectively on one side.	 The connecting rods (12) and connecting rod bearing caps (2) are cracked (broken). Do not mix up the connecting rods (12). Engine damage can occur otherwise.
		 While rotating the crankshaft (13), ensure that the connecting rods (12) do not tilt.
13	Remove connecting rod bolts (1) and remove connecting rod bearing caps (2).	 External Torx set	*001589760900
14	Mark upper connecting rod bearing shells (14) and lower connecting rod bearing shells (14) relative to the associated connecting rod (12) and connecting rod bearing cap (2).	 Do not mix up upper connecting rod bearing shells (14) and lower connecting rod bearing shells (14). Engine damage can occur otherwise.
15	Remove upper connecting rod bearing shells (14) and lower connecting rod bearing shells (14).
16	Remove crankshaft (13) from the crankcase (10).
17	Mark upper bearing shells (3) and upper thrust bearing shell (4) relative to the crankcase (10).	Only when reusing the upper bearing shells (3) and upper thrust bearing shell (4).
18	Remove upper bearing shells (3) and upper thrust bearing shell (4).
19	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 present in the oil duct, the connecting rod bores, and the oil ducts of the crankshaft (13) and the crankcase (10).
		Assembly cleaner	*BR00.45-Z-1028-04A
	Check
20	Measure crankshaft (13) and mount on bearings if necessary.		AR03.20-P-4355CD
21	Check bearing shells (3), thrust bearing shells (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 there are problems,
		
		Install new bearing shells (3) and thrust bearing shells (4) or crankshaft (13).
22	Check connecting rod bearing shells (14) 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 there are problems,
		
		Install new connecting rod bearing shells (14) and crankshaft (13).
23	Check remaining power unit components for wear and damage.	If problems occur,
		
		Replace corresponding power unit components.
24	Check connecting rod bolts (1) and replace if necessary.		AR03.10-P-6111-01T
		Connecting rod bolt	*BE03.10-P-1001-03I
	Install
25	Assign new bearing shells (3) and thrust bearing shells (4).	Only when installing new bearing shells (3) and thrust bearing shells (4) or crankshaft (13).
			AR03.20-P-4360-01CD
26	Wet upper bearing shells (3) and upper thrust bearing shell (4) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
27.1	Insert new upper bearing shells (3) and upper thrust bearing shell (4) in the crankcase (10).	Only when installing new upper bearing shells (3) and upper thrust bearing shell (4).
		 The oil grooves in the upper bearing shells (3) and upper thrust bearing shell (4) must point toward the respective collar of the crankshaft (13). The upper bearing shells (3) and upper thrust bearing shell (4) each have a retaining lug as an anti-twist lock.
27.2	Insert previously marked upper bearing shells (3) and previously marked upper thrust bearing shell (4) at the respectively marked location in the crankcase (10).	Only when reusing the upper bearing shells (3) and upper thrust bearing shell (4).
		 The oil grooves in the upper bearing shells (3) and upper thrust bearing shell (4) must point toward the respective collar of the crankshaft (13). The upper bearing shells (3) and upper thrust bearing shell (4) each have a retaining lug as an anti-twist lock.
28	Wet crankshaft bearing journals and connecting rod journals with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
29	Position crankshaft (13) in crankcase (10).
30	Wet connecting rod bearing shells (14) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
31	Insert upper connecting rod bearing shells (14) in the connecting rods (12).	 Insert connecting rod bearing shells (14) in a non-tilted manner in the connecting rod (12). The anti-twist lock of the upper connecting rod bearing shells (14) must sit in the cutouts of the connecting rods (12). Connecting rod bearing will otherwise be damaged.
		 Observe assignment of the upper connecting rod bearing shells (14) relative to the connecting rod (12).
32	Insert lower connecting rod bearing shells (14) in the connecting rod bearing caps (2).	 Insert lower connecting rod bearing shells (14) in a non-tilted manner into connecting rod bearing caps (2). The anti-twist lock of the lower connecting rod bearing shells (14) must sit in the cutouts of the connecting rod bearing caps (2). Connecting rod bearing will otherwise be damaged.
		 Observe marking of the lower connecting rod bearing shells (14) relative to the connecting rod bearing caps (2).
33	Place connecting rod bearing caps (2) on the crankshaft (13) and connecting rods (12) according to the applied markings.	 The connecting rods (12) and connecting rod bearing caps (2) are cracked (broken). Do not mix up or install laterally reversed. Connecting rod bearing will otherwise be damaged.
34	Screw in connecting rod bolts (1).		AR03.10-P-6111-02T
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
		 Tighten connecting rod bolts (1) only to the first and second stage of the tightening torque.
		 Bolt, connecting rod bearing cap to connecting rod	*BA03.10-P-1001-01R
		 External Torx set	*001589760900
35	Wet lower bearing shells (3) and lower thrust bearing shell (4) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
36	Install balance shaft housing (5).		AR03.20-P-1100CD
		 Install oil pan only after installation of the carrier with clamping device for the poly-V-belt.
37	Tighten connecting rod bolts (1) of the connecting rod bearing caps (2) to the third stage tightening torque.		AR03.10-P-6111-02T
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
		 Bolt, connecting rod bearing cap to connecting rod	*BA03.10-P-1001-01R
		 External Torx set	*001589760900
38	Install intermediate gears of the engine timing.		AR05.10-P-7620CD
		 Install timing case cover only after the installation of the oil pan.
39	Clean sealing surfaces on the end cover (7) and on the crankcase (10).	Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
40	Attach end cover (7) to the crankcase (10).
	Information on application of sealant to end cover of crankcase		AH01.40-N-1000-04WE
		 Apply sealing compound as per sealant path.
		 Ensure that the pilot bushings (8) are seated correctly.
		Sealant, Loctite 5970, 50 ml	*BR00.45-Z-1013-01A
		 Application gun	*112589002500
41	Screw in screws (6) on end cover (7).	 Bottom half of crankcase to crankcase	*BA01.40-P-1002-01X
42	Install radial shaft sealing ring (9) in the end cover (7).		AR03.20-P-3000CD
43	Install carrier with clamping device for poly-V-belt.	Engine 651 in model 166, 172, 204, 207, 212, 218, 221
		Engine 651 in model 166, 172, 204, 207, 212 (except 212.098/298), 218, 221	AR13.25-P-3300CD
44	Install oil pan.	Engine 651 in model 166	AR01.45-P-7500GQA
		Engine 651 in model 172	AR01.45-P-7500SLK
		Engine 651 in model 204 (except 204.9), 212 with transmission 711.6 except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 204 (except 204.9), 212 with transmission 722 except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 207 with transmission 711.6 Engine 651 in model 207, 218 with transmission 722 Engine 651 in model 212 with transmission 724.20 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500CD
		Engine 651 in model 204, 212 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500OMD
		Engine 651 in model 204.9 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.45-P-7500OND
		Engine 651 in model 221	AR01.45-P-7500SXA
45	Install timing case cover.		AR01.40-P-8000CD

Test specifications for connecting rod bolts

Number	Designation				Engine 651
BE03.10-P-1001-03I	Connecting rod bolt	Thread diameter		M	81
		Shank length	New	mm	47 (0,3)
			max.	mm	48

 Crankcase, timing case cover, end cover

Number	Designation			Engine 651
BA01.40-P-1002-01X	Bottom half of crankcase to crankcase	Stage 1	Nm	9
		Stage 2	°	-

 Connecting rod

Number	Designation				Engine 651
BA03.10-P-1001-01R	Bolt, connecting rod bearing cap to connecting rod	For initial tightening after cracking	Stage 1	Nm	5
			Stage 2	Nm	25
			Stage 3	°	180
		For subsequent tightening	Stage 1	Nm	5
			Stage 2	Nm	25
			Stage 3	°	90

112 589 00 25 00

Application gun

001 589 76 09 00

External Torx set

Repair materials

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant, Loctite 5970, 50 ml	A 003 989 98 20 10
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01
BR00.45-Z-1046-04A	Loctite 7063 (400 ml) cleaning spray	A 001 986 71 71 09

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