Remove/install crankshaft · ar0320p4351old · Mercedes-Benz WIS

AR03.20-P-4351OLD

Remove/install crankshaft

06.03.2020

Engine

651 in model 205, 253

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 19
27.04.2018	Check connecting rod bearing shells (9) and connecting rod journals for wear and damage, added.	Operation step 20

1	Connecting rod bolts
2	Connecting rod bearing cap
3	Bearing shells
4	Fitted bearing shell
5	Balance shaft housing
7	Connecting rod
8	Crankshaft
9	Connecting rod bearing shells
10	Crankcase

P03.20-2394-06

 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-8000OLD
2	Check basic position of camshafts.		AR05.20-P-6010OLD
		If the basic position of the camshafts is incorrect,
		
		Set basic position of camshafts.
			AR05.20-P-6020OLD
3	Check basic position of the balance shafts.		AR03.20-P-3637OLD
		If the basic position of the balance shafts is incorrect,
		
		Set basic position of the balance shaft.
			AR03.20-P-3638OLD
4	Remove oil pan.		AR01.45-P-7500OLD
5	Remove carrier with clamping device for poly-V-belt.		AR13.25-P-3300OLD
6	Remove end cover with radial shaft sealing ring from crankcase (10).		AR01.40-P-8920OLD
7	Loosen connecting rod bolts (1) of the connecting rod bearing caps (2).	 External Torx set	*001589760900
8	Remove intermediate gears of the timing assembly.		AR05.10-P-7620OLD
9	Remove balance shaft housing (5).		AR03.20-P-1100OLD
10	Place match marks on connecting rods (7) and connecting rod bearing caps (2) respectively on one side.	 The connecting rods (7) and connecting rod bearing caps (2) are cracked (broken). Do not mix up connecting rods (7). Engine damage can occur otherwise.
		 While rotating the crankshaft (8), ensure that the connecting rods (7) do not tilt.
11	Remove connecting rod bolts (1) and remove connecting rod bearing caps (2).	 External Torx set	*001589760900
12	Mark upper connecting rod bearing shells (9) and lower connecting rod bearing shells (9) relative to the associated connecting rod (7) and connecting rod bearing cap (2).	 Do not mix up connecting rod bearing shells (9). Engine damage can occur otherwise.
13	Remove connecting rod bearing shells (9).
14	Remove crankshaft (8) from crankcase (10).
15	Mark upper bearing shells (3) and upper thrust bearing shell (4) relative to the respective crankshaft main bearing.	Only when reusing the upper bearing shells (3) and upper thrust bearing shell (4).
16	Remove upper bearing shells (3) and upper thrust bearing shell (4) from crankcase (10).
17	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 (8) and the crankcase (10).
		Assembly cleaner	*BR00.45-Z-1028-04A
	Check
18	Measure crankshaft (8) and mount on bearings if necessary.		AR03.20-P-4355CD
19	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 problems occur,
		
		Install new bearing shells (3) and thrust bearing shells (4) or crankshaft (8).
20	Check connecting rod bearing shells (9) 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 occur,
		
		Install new connecting rod bearing shells (9) or crankshaft (8).
21	Check remaining power unit components for wear and damage.	If problems occur,
		
		Replace corresponding power unit components.
22	Check connecting rod bolts (1) and replace if necessary.		AR03.10-P-6111-01T
		Connecting rod bolt	*BE03.10-P-1001-03I
	Install
23	Assign new bearing shells (3) and thrust bearing shells (4).	When installing new bearing shells (3) and thrust bearing shells (4) or crankshaft (8).
			AR03.20-P-4360-01CD
24	Wet upper bearing shells (3) and upper thrust bearing shell (4) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
25.1	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 (8). The upper bearing shells (3) and upper thrust bearing shell (4) each have a retaining lug as an anti-twist lock.
25.2	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 (8). The upper bearing shells (3) and upper thrust bearing shell (4) each have 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 (8) in the crankcase (10).
28	Wet connecting rod bearing shells (9) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
29	Insert upper connecting rod bearing shells (9) in the connecting rods (7).	 Insert upper connecting rod bearing shells (9) in the connecting rod (7) in a non-tilted manner. The anti-twist lock of the upper connecting rod bearing shells (9) must sit in the cutouts of the connecting rods (7). Connecting rod bearing will otherwise be damaged.
		 Observe assignment of the upper connecting rod bearing shells (9) relative to the connecting rod (7).
30	Insert lower connecting rod bearing shells (9) in the connecting rod bearing caps (2).	 Insert lower connecting rod bearing shells (9) in the connecting rod bearing caps (2) in a non-tilted manner. The anti-twist lock of the lower connecting rod bearing shells (9) 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 (9) relative to the connecting rod bearing caps (2).
31	Place connecting rod bearing caps (2) on the crankshaft (8) and on the connecting rods (7) according to the applied markings.	 The connecting rods (7) and connecting rod bearing caps (2) are cracked (broken). Do not mix up or install laterally reversed. Connecting rod bearing will otherwise be damaged.
32	Screw in connecting rod bolts (1).	 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
33	Wet lower bearing shells (3) and lower thrust bearing shell (4) with engine oil.
	Specified engine oils (service) - Overview		BB00.40-P-0223-02A
34	Install balance shaft housing (5).		AR03.20-P-1100OLD
		 Install oil pan only after installation of the carrier with clamping device for the poly-V-belt.
35	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
36	Install intermediate gears of the engine management.		AR05.10-P-7620OLD
		 Install timing case cover only after the installation of the oil pan.
37	Install end cover with radial shaft sealing ring.		AR01.40-P-8920OLD
38	Install carrier with clamping device for poly-V-belt.		AR13.25-P-3300OLD
39	Install oil pan.		AR01.45-P-7500OLD
40	Install timing case cover.		AR01.40-P-8000OLD

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

 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

001 589 76 09 00

External Torx set

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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