Remove/install piston

AR03.10-T-7021B

Remove/install piston

11.12.08



Removing

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

1

Remove engine compartment encapsulation below the oil pan

For model 613.355/ 455/ 485

AR61.20-T-1105B

Model 613.364/ 365

AR61.20-T-1105C

2

Drain engine oil

 Drain oil into a suitable container.



*BA01.45-N-1002-01G

3

Remove transmission

For model 613.355/ 455/ 485

AR26.10-T-0020B

Model 613.364/ 365

AR26.10-T-0020C

4

Remove starter

AR15.30-T-7100B

5

Remove clutch

AR25.10-T-0050B

6

Remove flywheel

AR03.30-T-8002B

7

Remove timing case cover

AR01.40-T-8000B

8

Take off oil pan

AR01.45-T-7500B

9

Remove turbocharger.

On engine 441.980

AR09.40-T-6020C

On engine 402.970, 446.938

AR09.40-T-6020B

10

Remove cylinder heads

AR01.30-T-5800B

11

Remove alternator

AR15.40-T-5032B

12

Remove oil pump

13

Use a scraper to carefully remove combustion residues above the top land zone in the cylinder wall.

 Do not damage cylinder barrel in the process.

 This ensures that the piston rings are not damaged when the pistons are removed.

14

Remove connecting rod bearing cap (5)

 Turn crankshaft until connecting rod journal is at the bottom, loosen connecting rod bolts and remove.

Check before taking off whether the connecting rod bearing cap and the associated connecting rod are marked relative to each other; mark if necessary.

15

Remove piston (1) together with connecting rod (4) from the crankcase

Turn crankshaft in the process until the connecting rod journal stands at the upper point; push connecting rod with piston out of the cylinder liner.



- Use a plastic or wooden wedge when pressing out the connecting rod. Replace contact surface for connecting rod if damaged.

- Ensure that the remaining connecting rod bearing shell in the connecting rod is not damaged.

- Mark installation position of the connecting rod bearing shell.

16

Clamp connecting rod (4) and piston (1) in a vice

Use protective jaws for clamping.

17

Remove a circlip (3) from the piston boss

18

Press out piston pin (2) in direction of the removed circlip (3) and take piston (1) off the connecting rod (4)

When assembling, pay attention to marking of installation position of piston relative to piston pin and piston relative to connecting rod.

19

Remove second circlip (3) from piston boss

 with the round nose pliers.

20

Remove piston ring

AR03.10-T-7311B



*000589373700



Checking

 Clean all of the parts to be checked beforehand, in particular free up also the radial grooves and oil return bores for the piston from combustion residues.

21

Inspect piston stem and cylinder walls for wear

Quick calipers for internal measurements

Micrometer

Cylinder liner inner 

*BE01.40-N-1003-03F

Piston group marking

*BE03.10-N-1001-02I



Notes for assessing wear to cylinder wall in the case of dust damage

AH01.40-N-0001-01A



Notes for assessing piston wear from dust/particulate damage

AH03.10-N-0001-01A

22

Inspect piston crown for damage

23

Replace damaged pistons if necessary.

 If a new piston should be built-in then this should only be done with the relevant associated cylinder liner as a replacement part repair kit: 

Remove/install/seal cylinder liner

AR01.40-T-9324A

Assign piston to cylinder liner

AR03.10-T-7021-02B

Piston group marking

*BE03.10-N-1001-02I

Cylinder liner inner 

*BE01.40-N-1003-03F

24

Check piston ring for chippings on the coating; replace if necessary

Remove combustion residues beforehand from piston rings.

25

Measure piston ring end gap

AR03.10-T-7311-02B

Feeler gauge

End gap for piston rings

*BE03.10-N-1001-05G

 Represents the measured value not the specified value: 

Replace piston rings.

26

Inspect connecting rod and connecting rod bearings

AR03.10-T-6111B



Install

27

Install piston ring

AR03.10-T-7311B



*000589373700

28

Measure vertical clearance of piston rings

AR03.10-T-7311-01B

Feeler gauge

Side clearance of piston rings

*BE03.10-N-1002-05G

If the measured figure is greater than the specified value: 

Check piston ring and pistons; replace if necessary.

29

Install one circlip (3) into piston boss

30

Clamp connecting rod (4) in a vice

Use soft protective jaws (e.g. protective jaws made out of aluminum) to clamp in.

31

Fit piston (1) onto the connecting rod (4) and press piston pin (2) in direction of installed retaining ring (3)



- Pay attention in the process to marking of installation position of piston relative to piston pin and piston relative to connecting rod.

- Oil piston pin and insert into the piston and connecting rod by hand.

32

Install second circlip (3) into piston boss.

33

Check ease of movement of piston pin (2)

 By moving piston slightly back and forth.

34

Insert connecting rod bearing shells (7) into connecting rod (4) and lightly lubricate contact surface



- The lug of the connecting rod bearing shell must be located in the slot of the connecting rod.

- If connecting rod bearing shells are re-used, pay attention to installation marking.

35

Turn piston rings in such a way that joints are offset relative to each other lie respectively in installation position 45° to the right or left of the bolt eyes.

For a piston ring with spring expander the joint on spring expander is offset by 180° to the joint on piston ring.

36

Clean cylinder liner and piston contact surface using a clean rag and lubricate a little with engine oil.

37

Insert piston (1) with connecting rod (4) into the cylinder liner

Turn crankshaft in the process until connecting rod journal is at the top

The arrow in the piston crown must point in the direction of vibration damper.

38

Guide piston ring tensioning strap loosely over piston rings and tighten to outer diameter of the piston (1)

 The piston ring compressor band must be just movable.



*000589383100

39

Use handle of hammer to press piston (1) into cylinder liner until connecting rod bearing abuts the connecting rod bearing journal of the crankshaft

 Next introduce piston in the process into crankcase until the tensioning strap touches the cylinder crankcase.

40

Remove tensioning strap

 The piston rings must be within the cylinder bore.

41

Turn crankshaft while pulling the connecting rod until the connecting rod journal is at the bottom position

42

Insert connecting rod bearing shell (7) into the connecting rod bearing cap (5) and oil contact surface



- The lug of the connecting rod bearing shell must be located in the slot of the connecting rod bearing cap.

- If connecting rod bearing shells are re-used, pay attention to installation marking.

43

Install connecting rod bearing cap (5)

Screw in connecting rod bolts, pretighten to prescribed value and then tighten to specified rotation angle.



- Mark wrench socket to check tightening angle.

- Pay attention to marking on connecting rod bearing cap.

- Check length of the connecting rod bolt; replace if necessary.

Shank length (L)

*BE03.10-N-1008-01I



*BA03.10-N-1001-01H



*000589642100

44

Measure piston projection

AR03.10-T-7041-01B



*001589532100



*343589004000

Piston projection

*BE03.10-N-1002-02I

If the value is greater than the specified: 

Check connecting rod and pistons; replace if necessary.

45

Install oil pump

46

Installing oil pan

AR01.45-T-7500B

47

Install alternator

AR15.40-T-5032B

48

Install cylinder head

AR01.30-T-5800B

49

Pour in engine oil



*BF18.00-N-1001-01D

50

Install engine compartment encapsulation below the oil pan

For model 613.355/ 455/ 485

AR61.20-T-1105B

Model 613.364/ 365

AR61.20-T-1105C

Number

Designation

Engine 402.970

Engine 441.980

BE01.40-N-1003-03F

Cylinder liner inner 

Code letter B

mm

124.990 to 124.995

127.990 to 127.995

Code letter C

mm

124.995 to 125.000

127.995 to 128.000

Code letter D

mm

125.000 to 125.005

128.000 to 128.005

Code letter E

mm

125.005 to 125.010

128.005 to 128.010

Number

Designation

Engine 446.938

BE01.40-N-1003-03F

Cylinder liner inner 

Code letter B

mm

127.990 to 127.995

Code letter C

mm

127.995 to 128.000

Code letter D

mm

128.000 to 128.005

Code letter E

mm

128.005 to 128.010

Number

Designation

Engine 402.970

Engine 441.980, 446.938

BE03.10-N-1001-02I

Piston Ø

Group marking

BC

mm

124.790 to 124.795

127.780 to 127.785

BCD

mm

124.795 to 124.800

127.785 to 127.790

CDE

mm

124.800 to 124.805

127.790 to 127.795

DE

mm

124.805 to 124.810

127.795 to 127.800

BE03.10-N-1002-02I

Piston projection at TDC relative to upper edge of crankcase

mm

-0.03 to 0.33

0.07 to 0.43

Number

Designation

Engine 402.970

Engine 441.980, 446.938

BE03.10-N-1001-05G

Piston ring end gap

Keystone ring new

mm

0.25 to 0.4

0.35 to 0.5

Keystone ring used

mm

1.0

1.0

Taper-faced hook scraper ring, new

mm

0.25 to 0.4

-

Taper-faced hook scraper ring, run-in

mm

1.0

-

Taper-faced ring, new

mm

-

0.35 to 0.5

Taper-faced ring, run-in

mm

-

1.0

Bevel-edged ring with spring expander, new

mm

0.25 to 0.4

0.25 to 0.4

Bevel-edged ring with spring expander, run-in

mm

0.8

0.8

BE03.10-N-1002-05G

Piston ring vertical clearance

Keystone ring new

mm

0.082 to 0.137

0.047 to 0.102

Taper-faced hook scraper ring

mm

0.060 to 0.095

-

Taper-faced ring

mm

-

0.050 to 0.082

Bevel-edge ring with garter spring

mm

0.030 to 0.062

0.030 to 0.062

Number

Designation

Engine 402.970

Engine 441.980, 446.938

BE03.10-N-1008-01I

Connecting rod bolt - inner 

Thread dia.

M

16X1.5

16X11.5

Shank length (L)
when new

mm

67.5 (-0.3)

67.5 (-0.3)

Shank length (L)

mm

68.5

68.5

Number

Designation

Engine 402.970

Engine 441.980, 446.938

BA03.10-N-1001-01H

Bolt, connecting rod bearing cap to connecting rod

Stage 1

Nm

100

100

Stage 2

°

95

95

Number

Designation

Engine 402.970, 441.980

Engine 446.938

BA01.45-N-1002-01G

Oil drain screw on oil pan

Nm

80

80

Number

Designation

Engine 402.970

Engine 441.980

Engine 446.938

BF18.00-N-1001-01D

Engine oil

Filling capacity with oil filter

Liters

25.5

18.5

25.5

Filling capacity with oil filter and heat exchanger

Liters

28.5

-

28.5

Automatic engine oil replenishment reservoir

Liters

-

-

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

BB00.40-P-0228-01A

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

BB00.40-P-0228-05A