Remove/install piston

AR03.10-D-7021A

Remove/install piston

31.7.08



Removing

1

Remove engine

Engine 602.980

AR01.10-D-2400A

Engine 602.982

AR01.10-P-2400HD

Engine 602.983

AR01.10-P-2400GH

Engine 602.984/985

AR01.10-D-2400E

Engine 601.943

AR01.10-D-2400B

2

Remove cylinder head

Engine 602.980

AR01.30-D-5800R

Engine 602.982/983

AR01.30-P-5800HW

Engine 602.984/985

AR01.30-D-5800S

Engine 601.943

AR01.30-D-5800B

3

Remove oil pump

Engine 602.982/983

AR18.10-P-6020HA

Engine 601.943, 602.980/984/985

AR18.10-D-6020D

4

Unscrew connecting rod bearing cap (1)

 Connecting rod (2) and connecting rod bearing cap (1) are marked together (arrow).

5

Remove connecting rod (2) together with pistons (4) by lifting up and out

 If the pistons are worn, the travel direction arrows may no longer be visible because of carbon deposits. For this reason, remove carbon deposits to render travel direction arrow visible.

6

Use a screwdriver to press out piston pin locking element (5)

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

7

Press out piston pin (6) and take off piston (4)

 Piston design

GF03.10-P-7021-01A



Install

8

Check connecting rod bushing inside diameter

if excessive wear present 

Installing a new connecting rod bushing

AR03.10-D-6111-03A

*BE03.10-N-1006-01D

*BE03.10-N-1007-01D

*BE03.10-N-1008-01D

*BE03.10-N-1009-01D

*BE03.10-N-1010-01D

9

Oil piston pin (6) and connecting rod bushing

10

Assemble piston (4) and connecting rod (2)

 Install piston with arrow pointing in direction of travel.

 The marking and the retaining grooves in the connecting rod are located on the left (at the inlet side).

11

Insert piston pin (6) by hand.

12

Insert piston pin locking element (5) into the groove (arrow) on the piston.

13

Oil cleaned cylinder bores, connecting rod journals, connecting rod bearing shells and pistons (4)

14

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



*000589041400

15

Install piston (4) with arrow pointing in direction of travel

 Reinstall piston at the same point.

Pay attention to piston assignment

16

Check connecting rod bolts

and replace if necessary

AR03.10-D-6111-01A

*BE03.10-N-1012-01D

17

Install connecting rod bearing cap (1)

 Install connecting rod bearing cap (1) and connecting rod (2) with the markings (arrows) pointing to each other.

18

Tighten connecting rod bolts

AR03.10-D-6111-02A



*BA03.10-N-1001-01A

19

Rotate crankshaft and check for unobstructed movement

20

Install oil pump

Engine 602.982/983

AR18.10-P-6020HA

Engine 601.943, 602.980/984/985

AR18.10-D-6020D

21

Measure piston projection

 Install cylinder head gasket of standard thickness or cylinder head gasket of repair thickness (1.85 mm thick) depending on piston projection

AR03.10-D-7041-01A

*BE03.10-N-1001-02E

*BE03.10-N-1002-02E



*001589532100



*343589004000

22

Install cylinder head

Engine 602.980

AR01.30-D-5800R

Engine 602.982/983

AR01.30-P-5800HW

Engine 602.984/985

AR01.30-D-5800S

Engine 601.943

AR01.30-D-5800B

23

Install engine

Engine 602.980

AR01.10-D-2400A

Engine 602.982

AR01.10-P-2400HD

Engine 602.983

AR01.10-P-2400GH

Engine 602.984/985

AR01.10-D-2400E

Engine 601.943

AR01.10-D-2400B

Number

Designation

Engine
601.943

BE03.10-N-1006-01D

Connecting rod bushing inside (d)

mm

26.012 to 26.018

See picture

-

BE03.10-N-1007-01D

Connecting rod bushing outside Ø

mm

28.575 to 28.600

BE03.10-N-1008-01D

Connecting rod bushing basic bore (d1)

mm

28.500 to 28.521

See picture

-

BE03.10-N-1009-01D

Piston pin play in connecting rod bushing

mm

0.007 to 0.018

BE03.10-N-1010-01D

Peak-to-valley height (Rz) inside connecting rod bushing

μm

5

BE03.10-N-1012-01D

Connecting rod bolt

Length (L)

New

mm

52 -0.3

max.

mm

52.9

Number

Designation

Engine
602.980/982/
983/984/985

BE03.10-N-1006-01D

Connecting rod bushing inside (d)

mm

28.018 to 28.024

See picture

-

BE03.10-N-1007-01D

Connecting rod bushing outside Ø

mm

30.575 to 30.600

BE03.10-N-1008-01D

Connecting rod bushing basic bore (d1)

mm

30.500 to 30.525

See picture

-

BE03.10-N-1009-01D

Piston pin play in connecting rod bushing

mm

0.007 to 0.018

BE03.10-N-1010-01D

Peak-to-valley height (Rz) inside connecting rod bushing

μm

5

BE03.10-N-1012-01D

Connecting rod bolt

Length (L)

New

mm

52 -0.3

max.

mm

52.9

Number

Designation

Engine
601.943

Engine
602.980/982/
983/984/985

BE03.10-N-1001-02E

Piston projection (a) with new cylinder crankcase

mm

0.74 to 0.96

0.835 to 1.065

See picture

AR03.10-D-7041-01A

AR03.10-D-7041-01A

BE03.10-N-1002-02E

Piston projection (a) with reworked cylinder crankcase

mm

0.96 to 1.16

1.035 to 1.265

See picture

AR03.10-D-7041-01A

AR03.10-D-7041-01A

Number

Designation

Engine
601.943

Engine 602.980/982/983/984/985

BA03.10-N-1001-01A

Connecting rod bolt

Stage 1

Nm

42

42

Stage 2

°

90

90