Remove/install piston

AR03.10-D-7021D

Remove/install piston

5.8.11



Removing

1

Remove engine

Engine 611

AR01.10-D-2400F

Engine 612

AR01.10-D-2400G

2

Remove oil pan

Engine 611

AR01.45-D-7500F

Engine 612

AR01.45-D-7500G

3

Remove oil pump

 Only when removing piston on
cylinder 1 

Engine 611

AR18.10-D-6020E

Engine 612

AR18.10-D-6020F

4

Remove cylinder head

AR01.30-D-5800E

5

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

 Mark connecting rod (4) and connecting rod bearing cap (7) to each other, pointing to the exhaust side (arrow). Connecting rod (4) and connecting rod bearing cap (7) are cracked and must not be mixed up, and replaced only together.

6

Remove connecting rod (4) together with piston (1) by lifting up and out

 The pistons are marked with direction arrows pointing in direction of travel.
If the pistons are used, the stamped direction arrows may no longer be visible; mark pistons with direction arrows pointing in direction of travel, if necessary.

7

Use a screwdriver to press out retaining ring (3)

 Do not damage piston (1). Use a clean cloth as a base.

8

Press out piston pin (2) and take piston (1) off the connecting rod (4)



Install

9

Oil piston pin (2) and connecting rod bush

10

Assemble piston (1) and connecting rod (4)

 Assemble piston (1) and connecting rod (4) so that the arrow on the piston is pointing in direction of travel.
The marking on the connecting rod (4) is pointing toward the exhaust side.

11

Push in piston pin (2) by hand

12

Insert retaining ring (3) into the groove on the piston

 Do not damage piston (1). Use a clean cloth as a base.

13

Oil cleaned cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons (1)

 Do not swap connecting rod bearing shells (5 and 6).

14

Fit on piston ring clamp (9) for piston rings, tension

 Offset piston ring end gaps by 120°.



*000589041400

15

Press in piston (1) with arrow pointing in direction of travel (use handle of hammer)

 The marking on connecting rod (4) is pointing toward the exhaust side.



Checking

16

Check connecting rod bolts

AR03.10-P-6111-01HB

*BE03.10-P-1001-03D

17

Insert connecting rod bearing shell (6) into connecting rod bearing cap (7)

18

Fit connecting rod bearing cap (7) and connecting rod bearing shell (6) onto the connecting rod (4) and attach

 Pay attention to marking of connecting rod bearing cap (7) relative to connecting rod (4) (arrow).



*BA03.10-P-1001-01I

19

Rotate crankshaft and check for unobstructed movement

20

Install oil pump

Engine 611

AR18.10-D-6020E

Engine 612

AR18.10-D-6020F

21

Install oil pan

Engine 611

AR01.45-D-7500F

Engine 612

AR01.45-D-7500G

22

Measure piston projection

 Install cylinder head gasket of normal thickness or cylinder head gasket of repair thickness depending on piston projection.

AR03.10-P-7041-01B

Piston projection

*BE03.10-N-1001-02P

23

Install cylinder head

AR01.30-D-5800E

24

Install engine

Engine 611

AR01.10-D-2400F

Engine 612

AR01.10-D-2400G

Number

Designation

Engine
611.981/983/987

Engine
612.981

BE03.10-N-1001-02P

Piston projection (a) with new crankcase

-

mm

0.38 to 0.62

0.38 to 0.62

See picture

AR03.10-P-7041-01B

AR03.10-P-7041-01B

Number

Designation

Engine
611, 612.961/962/963/965/966/981,
613

BE03.10-P-1001-03D

Connecting rod bolt

Thread diameter

M

81

Shank length

New

mm

47 (0.3)

max.

mm

48

Number

Designation

Engine 611, 612 except 612.990, 613

BA03.10-P-1001-01I

Bolt, connecting rod bearing cap to connecting rod

Stage 1

Nm

5

Stage 2

Nm

25

Stage 3

°

90