Piston removal and installation

AR03.10-T-7021CB

Piston removal and installation

9.4.03



Remove

1

Open maintenance flap



- engine compartment flap at rear,

- interior compartment flap above engine.

2

Raise vehicle.

AR00.60-T-1000B

3

Remove bottom engine compartment paneling

AR61.20-T-1105CA

4

Drain engine oil



Engine - oil and filter change

On model 613.367

AP18.00-T-0101CB



Engine - oil and filter change

On model 613.368

AP18.00-T-0101CA

5

Remove oil pan

AR01.45-T-7500BA

6

Remove cylinder heads

On model 613.367

AR01.30-T-5800CB

On model 613.368

AR01.30-T-5800CA

7

Remove oil pump

AR18.10-T-6020BA

8

Carefully remove combustion residues in the top land zone of the cylinder using a scraper

 Proceed carefully, do not damage cylinder barrel.

9

Remove conrod bearing cap (5)

 Rotate crankshaft until the corresponding connecting rod journal is located at bottom.

 Because of risk of mix up, check if the connecting rod bearing cap and the matching conrod are marked relative to each other, mark if necessary.

10

Press piston (1) with conrod (4) out of crankcase and remove

 Rotate crankshaft until the corresponding connecting rod journal is located at top

Use a wooden or plastic rod for pressing out. Do not damage the connecting rod bearing shell remaining in the conrod.Mark installation position of conrod bearing shell.

11

Carefully clamp conrod (4) together with piston (1) in a vice

 Use soft protective jaws.

 Danger!

Risk of injury with trapped or crushed fingers when working on springs or spring-loaded components

Use only approved tensioning devices; additionally shield off hazardous area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

12

Remove one circlip (3) from the piston boss

13

Press out piston pin (2)

Press out piston pin (2) in direction of the removed circlip and remove piston (1) from conrod (4)

 In order to prevent engine damage through incorrect assembly, check matching pistons, piston pins and connecting rods for existing marking, attach if necessary.

14

Remove second circlip (3) from the piston boss

15

Remove piston rings

AR03.10-T-7311BB

 

Check, measure

16

Inspect pistons and connecting rods for wear and damage

AR03.10-T-0001CB



Install

 Danger!

Risk of injury with trapped or crushed fingers when working on springs or spring-loaded components

Use only approved tensioning devices; additionally shield off hazardous area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

17

Install one circlip (3) into the piston boss

18

Carefully clamp conrod (4) in the vice

 Use soft protective jaws.

19

Fit piston (1) onto conrod (4) and install piston pin (2) by hand

 In order to prevent engine damage through incorrect assembly, observe marking of matching pistons, piston pins and connecting rods.

 Oil piston pin.

20

Install second circlip (3) into the piston boss.

21

Check piston pin (2) for easy movement by slightly moving it in and out

22

Install piston rings

AR03.10-T-7311BB

23

Insert conrod bearing shell (7) into conrod (4) and oil tread slightly

 If the old connecting rod bearing shells are reused, observe assignment to conrod. The lug of the conrod bearing shell must be located in the slot of the conrod.

24

Clean cylinder liner and tread of piston and slightly oil

 Use clean rag and fresh engine oil. Mount joints of piston ring offset relative to each other.

25

Guide loose tensioning strap via the piston rings and twist



*000589383100

26

Insert piston (1) with conrod (4) into the cylinder liner

 The arrow in the piston crown must point in the direction of the vibration damper. Press in piston (1) using a hammer handle so far, until the connecting rod bearing shell (7) rests against the connecting rod journal of the crankshaft.

27

Insert connecting rod bearing shell (7) into the connecting rod bearing cap (5) and oil tread lightly

 If the old connecting rod bearing shells (7) are reused, observe assignment to connecting rod bearing cap.-The lug of the conrod bearing shell must be located in the slot of the conrod bearing cap.

28

Install conrod bearing cap (5)

 Observe assignment to conrod (4).



*BA03.10-N-1001-01H



*000589642100

29

Measure piston projection

AR03.10-T-7041-01A

*BE03.10-N-1005-02I



*001589532100



*343589004000

30

Install oil pump

AR18.10-T-6020BA

31

Install cylinder heads

On model 613.367

AR01.30-T-5800CB

On model 613.368

AR01.30-T-5800CA

32

Installing oil pan

AR01.45-T-7500BA

33

Pour in engine oil



Engine - oil and filter change

On model 613.367

AP18.00-T-0101CB



Engine - oil and filter change

On model 613.368

AP18.00-T-0101CA

34

Install lower engine-compartment encapsulation panel

AR61.20-T-1105CA

35

Lower vehicle

AR00.60-T-1000B

36

Close maintenance flaps



- engine compartment flap at rear,

- interior compartment flap above engine.

Number

Designation

Engine
457.941/942

Engine
457.944

BE03.10-N-1005-02I

Piston projection at TDC relative to contact face of crankcase

mm

0.224...0.715

0.224...0.715

Number

Designation

Engine 457.941/
942

Engine 457.944

BA03.10-N-1001-01H

Bolt of conrod bearing cap to conrod

1st stage

NM

100

100

2nd stage

°

90

90