1982-1993 Mercedes-Benz 190 / 190D / 190E (W201) Service & Repair Manual

03 Crankshaft assembly Job No. Checking, replacing and tightening connecting rod bolts .......................... 03 - 310 Reconditioning and squaring connecting rods .................................. 03 - 313 Removal and installation of pistons .......................................... - 316 Modifications to pistons .................................................. -317 Checking and reconditioning crankshaft ....................................... - 318 Installation of crankshaft and connecting rod bearings ............................. - 320 Modifications to crankshaft ................................................ - 321 Replacing front crankshaft radial sealing ring ................................... - 324 Removal and installation of pilot bearing in crankshaft ............................. - 330 Removal and installation of crankshaft pulley and hub ............................. - 341 Checking and correcting adjustment of TDC sensor .............................. - 345 Removal and installation of crankshaft sprocket ................................. - 350 Removal and installation of flywheel and driven plate ............................. - 410 Refinishing flywheel ..................................................... - 420 Replacing ring gear ..................................................... - 430 0311

03-310 Checking, replacing and tightening connecting rod bolts P03-0100-13 Stretch bolt dia. (dimension c) . . . . . . . . . . . . . . measure, minimum dia, If shaft dia. is less than connecting rod bolts. Threads on connecting rod bolts , . . . . . . . . . , . oil. = 7.1 mm. 7.1 mm replace Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . initially tighten to 30 Nm and then tighten to rotation angle of 90 - 100”. AWarning Do not use torque wrench with flexible shaft for rotation angle tightening. Note Estimate angle of rotation. For this purpose insert adjustable torque wrench in break position (locked) into ratchet. Position adjustable torque wrench with plug-in ratchet lengthwise in relation to engine and continue to turn until it is transverse in relation to engine. 03.10 - 310/l

Dimensions Part No. 102 038 00 71 Thread M 9x1 Necked down shaft dia. (c) in new condition 7.4 - 0.1 Minimum necked down shaft dia. (c) Length (L) in new condition 52 - 0.3 Tightening torques and rotation angles Initial tightening torque Rotation angle Special tool 001 589 72 21 00 00 03.10 - 31012

03-313 Reconditioning and squaririg connecting rods Prellmlnary jobs: Pistons removed (03-316). 168 1-B--] PO3-0097.15 Connecting rod bolts (168) and sleeves (167) . . . oil. Connecting rod bearing cap . . . . . . . . . . . . . . . . attach without connecting rod bearing shells (165, 165a), remove, 30 Nm (item 1). Basic bore (D) . . . . . . . . . . . . . . . . . . . . . . . . . measure, max. 51.619 mm, if dimension is exceeded, machine bearing cap down max. 0.02 mm (item 2). Connecting rod bushing (169) . . . . . . . . . . . . . . press in, approx. 2450 N and machine or ream out (items 3, 4). Connecting rod (166) . . . . . . . . . . . . . . . . . . . . touch up lateral thrust surfaces (item 5). Connecting rod (166) . . . . . . . . . . . . . . . . . . . . square with connecting rod tester (items 6 - 8). Caution! The connecting rod bearing bore and connecting rod bushing bore must be parallel to one another. 03.10 - 313/l

Data Center of connecting rod bearing bore to center of connecting rod bushing bore (L) Engine 602 603.96 148.97 149.03 Engine 603.970 144.97 145.03 Width of connecting rod (B) at connecting rod bearing bore and connecting rod bushing bore 1 st version 2nd version 23.974 24.026 22.000 21.948 Basic bore for connecting rod bearing shells 51.600 51.619 1 st version 29.500 29.521 Basic bore for connecting rod bushing (D 1) 2nd version 28.500 Engine 602.91 -+----- 28.521 Engine 603.96 30.500 602.96 - 30.525 1 st version 29.560 29.600 Connecting rod bushing 0 2nd version 28.575 28.600 Engine 603.96 - 30.575 30.600 Connecting rod bushing 0 (D 2) 1 st version 27.018 Engine 27.024 602.91 2nd version 26.000 26.000 Engines 602.96, 603.96/97 28.000 28.000 Roughness of connecting rod bushing, inside 0.005 Permissible offset of connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length 0.1 Permissible deviation of parallel axis alignment: Connecting rod bearing bore in relation to connecting rod bushing bore with reference to 100 mm length 0.045 Permissible difference in weight within engine 49 03.10 - 31312

Note on connecting rod versions The axial play of the connecting rods is limited by the piston pin eye (piston-guided connecting rods). For this purpose appropriate thrust surfaces (arrow) are cast on the piston pin eye. Connecting rods for engines 602.96, 603.96/97 are not bored hollow. Overheated connecting rods Connecting rods which have been overheated due to a damaged bearing (blue discoloration) cannot be reused. Matching connecting rods and connecting rod bearing caps are marked (arrow). The connecting rod shafts should not have any transverse score marks or notches. Replacement connecting rods are supplied with machined connecting rod bushings. PO3-0099- 15 PO%2088-13 Connecting rod width Connecting rod width (B) on engines 602 and 603 from start of production is 22 mm. 03.10 - 313/3

Engines 602.91, 603.91 starting 1 l/85 The connecting rods are heat treated before machining to reduce the tendency to warp. Production beakpoint: 1 l/85 not registered Engine 603.960 starting 01188 On these engines there are 3 bores (arrows) with a dia. of 4.5 mm in the connecting rod eye for lubrication of the piston pin. P03-0101-13 03.10 - 313/4

. Engines 602.961, 602.962, 603.970 and 602.96, 603.96 starting 09188 On these engines the connecting rod eye is now equipped with 2 bores (arrows) with a dia. of 4.5 mm. Engines 602.91, 603.91 Shaft cross section of piston rods reduced (stan- dardized with M 102) and material changed 49 Mn VS 3 (was CK 45 V 7 50). Production breakpoint: 09 - 12/86 . not reglstered Engine 602.91 Shaft cross section was changed back, material 49 Mn VS 3. 03.10 - 31315

Production breakpoint: W86 . . not registered Tightening torque Connecting rod bolts Initial tightening torque Rotation angle 30 Nm go- 100" Special tool 001 589 66 21 00 \ 00 / Commercially available tools Connecting rod straightener e.g . Hahn & Kolb, D-7000 Stuttgart Model BC 503 Runout gauge e.g . Carl Mahr, D-7300 Esslingen Model 844 N Reconditioning 1 Install connecting rod bearing cap without connecting rod bearing. For this purpose lubri- cate threads and bolt head contact surface and tighten to 30 Nm. 03.10 - 31316

1982-1993 Mercedes-Benz 190 / 190D / 190E (W201) Service & Repair Manual

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