Remove/install piston

AR03.10-D-7021C

Remove/install piston

31.7.08



Removing

1

Remove cylinder head

 Intake manifold and exhaust manifold remain on the cylinder head.

AR01.30-D-5800C

2

Remove oil pan

AR01.45-D-7500C

3

Take off connecting rod bearing cap (7) and remove connecting rod bearing shell (6)

 Connecting rod (4) and connecting rod bearing cap (7) have matching marks (arrow).

4

Check connecting rod bolts (8)

AR03.10-S-6111-01A

*BE03.10-N-1001-03A

5

Remove connecting rod (4) together with pistons (3) by lifting up and out

 If the pistons are used, the stamped direction arrows or color markings may no longer be visible; therefore mark pistons (3) with direction arrows pointing in direction of travel.

6

Remove retaining ring (1)

 Do not damage piston (3) in the process. If necessary, place a clean cloth underneath.

7

Press out piston pin (2) and take piston (3) off the connecting rod (4)



Install

8

Oil piston pin (2) and connecting rod bushing

9

Assemble piston (3) and connecting rod (4)

 Assemble piston (3) and connecting rod (4) such that the arrow or color marking on the piston crown is pointing in the direction of travel.
The marking and keyway on the connecting rod (4) are pointing toward the intake side.

10

Push in piston pin (2) by hand

11

Insert retaining ring (1) into the groove (arrow) at the piston

12

Oil cleaned cylinder bores, connecting rod journals, connecting rod bearing shells (5, 6) and piston (3)

13

Insert connecting rod bearing shell (5) with oil hole into the connecting rod (4)

14

Turn piston rings with joints offset 120° to one another.

15

Fit on tensioning strap (7) for piston rings and tension



*000589041400

16

Install piston (3) with direction arrow or color marking pointing in direction of travel

17

Insert connecting rod bearing shell (5) into connecting rod bearing cap (7)

18

Fit connecting rod bearing cap (7) with connecting rod bearing shell (5) onto connecting rod (4) and bolt tight

 Attach connecting rod bearing cap (7) and connecting rod (4) with the markings (arrows) pointing to each other.

AR03.10-S-6111-02A



*BA03.10-N-1001-01A

19

Rotate crankshaft and check for unobstructed movement

20

Measure piston projection

 If the specified value is not reached, determine cause and specify appropriate repair measure.

*BE03.10-N-1001-02C

21

Installing oil pan

AR01.45-D-7500C

22

Install cylinder head

AR01.30-D-5800C

23

Check for leaks

Number

Designation

Engine 111.979

BE03.10-N-1001-03A

Connecting rod bolts

Thread diameter

M

91

Length of shank when new

mm

51.7-52.0

Max. shank length

mm

52.9

Number

Designation

Engine 111.979

BE03.10-N-1001-02C

Piston projection

mm

1.02-1.38

Number

Designation

Engine 111.979

BA03.10-N-1001-01A

Connecting rod bolt

Stage 1

Nm

42

Stage 2

°

90