Remove/install piston

AR03.10-B-7021C

Remove/install piston

18.05.2020

Engine

457.9 in model 382, 634

Engine

457.9 in model 693, 695, 696

Engine

457.9 in model 695

1

Piston

8

Cylinder liner

2

Piston pin

9

Shims to immobilize the liner

3

Locking ring

10

Spacers

4

Connecting rod

11

Cylinder head bolts

5

Connecting rod cap

12

Device to turn the engine

6

Connecting rod bolt

7

Connecting rod shell

L

Connecting rod screw length

1

Piston

14

Rings compression belt

4

Connecting rod

A

Piston distance at TDC

13

Oil injector



Remove

1

Remove the cylinder head

.

AR01.30-B-5800F

2

Remove oil sump

Engine 457 696.080, 457.928/931

AR01.45-B-7500E

Engine 457.907/908/909/915/916/927/932

AR01.45-B-7500F

3

Remove any combustion residues from the inner top portion of the cylinder liner (8)


Be careful not to damage the inner surface of the cylinder liner (8).
Take care also to avoid damaging the piston rings (1) when removing it.

4

Install the engine turning device (12) on the flywheel housing

Engine 457.9 in Type 382.1, 634.0

AR03.30-B-1600-03A

 Cranking device

*407589006300

5

Lock the cylinder liner (8), attaching it to the crankcase by means of two shims (9) to lock the liner



.

WF58.50-B-0160-01A



Spacers

.

WF58.50-B-0160-02A

 Support the shims to lock the liner (9) on the outer edge of the liner (8) and fix them with the bolts (11) and the spacers (10), in the diametrically opposed threaded holes of head fixing and tighten the bolts (11) up to 30 Nm.

6

Remove the connecting rod cap (5)

.

AR03.10-B-6111B


In the case of damage to the cap coupling faces and the connecting rod (5),
replace the entire connecting rod (4).

 Turn the crankshaft until obtaining a favorable position to loosen and remove the connecting rod bolts (6) and cap (5), being careful not to damage the connecting rod (4).

7

Remove the piston (1) with the connecting rod (4)

.

AR18.00-B-4000C


Be careful not to damage the connecting rod (4), the crankshaft journal, the inner surface of the cylinder liner (8) and the piston cooling nozzle.
If necessary, correct or replace the piston cooling nozzle.

 Turn the crankshaft until the piston (1) to be removed reaches the TDC.
Push the connecting rod (4) with the piston (1) towards outside the cylinder, with the aid of a wooden or plastic handle.

8

Remove the bearing shells (7) from the connecting rod (4) and the connecting rod cap (5)

 Mark the bearing shells (7) and their respective connecting rods (4) and caps (5).
This procedure will allow, in the case of reuse, that the shells (7) are installed in their original positions.

 The connecting rod shell (7) mounted on the connecting rod (4) receives special treatment on the friction surface (to withstand higher loads), different from the connecting rod shell (7) mounted to the cap (5).

9

Remove the locking rings (3)

 Secure the connecting rod (4) on a vise with its jaws protected with a soft material.

10

Remove the piston pin (2) and remove the piston (1) from the connecting rod (4)

 Should the piston (1) be reused, keep it with its respective pin (1).

.Basic wrist pin bore diameter in piston

*BE03.10-B-1004-02D

.Wrist pin diameter

*BE03.10-B-1005-02D



Check

11

Check the cylinder liner (8) and the piston (1) for damage and/or wear

Engine 457.9 in Type 634.0

AR01.00-B-0001A

.

AR01.40-B-9202C

 Check the engine for damage caused by dust.

 Check the cylinder liner (8).

 Replace any pistons (1) showing cracks or damage in the grooves of the lock rings (3), signs of frictional damages and erosion.

12

Check the status of the rings for wear and/or tear at the outer layer

.

AR03.10-B-7311B

 Replace the damaged rings.

13

Check the matching between the piston (1) and the cylinder liner (8)

.

AR03.10-B-7021-02B

 This procedure is indispensable when replacing the piston (1) and/or cylinder liner (8).

14

Check the connecting rod (4) for irregularities

.

AR03.10-B-6111B

15

Check the connecting rod shells (7) and the respective crankshaft journal

.

AR03.10-B-6111-06B

 Installation: Install the connecting rod bearing, measure it.

16

Check the connecting rod screw length (L) of the connecting rod cap (5)

 Replace the bolt (6) in case the max. length (L) is exceeded.

.Connecting rod cap bolt

*BE03.10-B-1001-01G



Install

17

Mount the piston (1) on the connecting rod (4), insert the piston pin (2) manually and install the lock rings (3) in the grooves of the piston (1)

Notes on installing pistons and connecting rods

.

AH03.10-N-2200-02C


Care must be taken when assembling the piston (1)
Otherwise, it may collide with the piston cooling nozzle

 Note that, when assembling the engine, the arrow at the top of the piston (1) is oriented towards the front of the engine and the connecting rod (4), with the longer side (mating face with the cap) facing the injection units.

 Lubricate the piston pin (2) with engine oil.

18

Place the rings on the piston (1) so that their openings are out of phase from each other by approximately 120°

 Lubricate the piston (1) and the rings with engine oil.

19

Install the ring compression belt (14) on the piston (1) and compress the rings on the outer diameter of the piston.

 Tensioning strap

*000589383100

20

Install the connecting rod shell (7) on the connecting rod (4)

 Pay attention to the marks made during the removal. Fit the connecting rod shell (7) tang in the connecting rod groove (4).

 Lubricate the friction surface of the connecting rod shell (4)..

21

Insert the connecting rod (4) with the piston (1) until the ring compression belt (14) touches the cylinder liner

.

AR18.00-B-4000C


Be careful not to damage the oil spray nozzle (13)
If necessary, correct or replace the oil nozzle (13).

 The arrow on the piston bottom (1) should be oriented to the front of the engine and the connecting rod (4), with the longest side (mating face with the cap) facing the nozzle units.

22

Carefully push the piston (1) up to the connecting rod (4) shell (7) seats on the crankshaft journal

 Be careful not to damage the connecting rod (4), the crankshaft journal and the cylinder liner surface (8).

23

Install the connecting rod shell (7) in the connecting rod cap (5)

 Check the marks made during the removal and fit the tab of the connecting rod shell (7) in the groove of the connecting rod cap (5).

 Lubricate the friction surface of the connecting rod shell (7)..

24

Install the connecting rod cap (5) with the bearing shell (7) on the connecting rod (4)

 Pay attention to ensure that the connecting rod (4) identification numbers match the numbers on the corresponding cap (5), and that they are facing the same side.
Manually press the cap (5) on the crankshaft journal, fitting it into the connecting rod (4).

25

Install the bolts (6) attaching the cap (5) to the connecting rod (4)


Do not reuse the connecting rod screw (L) above the maximum permitted limit.
If necessary, use new bolts.

 Slightly lubricate the thread and the seating face of the bolt head.

 .Connecting rod cap fastening bolts

*BA03.10-B-1001-01C

.Connecting rod cap bolt

*BE03.10-B-1001-01G

26

Check the axial play of the connecting rod and rotate the crankshaft to check its free movement

.Axial play of the connecting rod shell (bearing)

*BE03.10-B-1008-01G

27

Check the distance between the piston crown (1) at the PMS and the block surface

.

AR03.10-B-7041-01TC

.Distance between piston top face at TDC above cylinder block deck surface

*BE03.10-B-1003-02D

28

Remove the engine turning device (12) from the flywheel housing

.

AR03.30-B-1600-03A

 Cranking device

*407589006300

29

Remove the shims used to immobilize the liner (9)

 Loosen the head bolts (11) and remove them together with the spacers (10) and shims (9).

30

Install the oil sump

Engine 457 in Type 696.080 Engine 457.928/931

AR01.45-B-7500E

Engine 457.907/908/909/915/916/927/932

AR01.45-B-7500F

31

Install the cylinder head

.

AR01.30-B-5800F

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

Engine 457.9, 460.984 with Code MS5

BE03.10-B-1001-01G

Connecting rod cap bolt

Thread diameter

mm

16x1,5

16x1,5

Length of new conditions rod

mm

67,2...67,5

67,2...67,5

Rod admissible length

mm

68,5

68,5

Test values for the piston

Number

Designation

Engine 457.9 except for Code MS5

Engine 457.9 with Code MS5

BE03.10-B-1003-02D

Distance between piston top face at TDC above cylinder block deck surface

mm

0,224...0,715

0,224...0,715

Test values for the piston

Number

Designation

Engine 457.9 except for Code MS5

Engine 457.9 with Code MS5

BE03.10-B-1004-02D

Basic wrist pin bore diameter in piston

mm

52,010...52,018

52,010...52,018

Test values for the piston

Number

Designation

Engine 457.9 except for Code MS5

Engine 457.9 with Code MS5

BE03.10-B-1005-02D

Wrist pin diameter

mm

51,992...51,998

51,992...51,998

Connecting rod test values

Number

Designation

Engine 457.9 except for Code MS5

Engine 457.9, 460.984 with Code MS5

BE03.10-B-1008-01G

Axial play of the connecting rod shell (bearing)

mm

0,130...0,292

0,130...0,292

 Connecting rod

Number

Designation

Engine 457.9; 460.984

BA03.10-B-1001-01C

Connecting rod cap fastening bolts

Initial tightening

Nm

100...115

Final angular tightening

graus

90...100