AR03.10-T-7021CB | Piston removal and installation | 9.4.03 |
ENGINE 457.941 in MODELNMB613.368
ENGINE 457.944 in MODELNMB613.367
T03.10-0002-06
1 Pistons
2 Piston pin
3 Circlip
4 Connecting rods
5 Conrod bearing cap
6 Connecting rod bolt
7 Conrod bearing shell
L Length of conrod bolt
Arrows Marking
| Remove | ||
1 | Open maintenance flap | - engine compartment flap at rear, - interior compartment flap above engine. | |
2 | Raise vehicle. | ||
3 | Remove bottom engine compartment paneling | ||
4 | Drain engine oil | ||
| Engine - oil and filter change | On model 613.367 | |
| Engine - oil and filter change | On model 613.368 | |
5 | Remove oil pan | ||
6 | Remove cylinder heads | On model 613.367 | |
On model 613.368 | |||
7 | Remove oil pump | ||
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. | |
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 | ||
| Check, measure | ||
16 | Inspect pistons and connecting rods for wear and damage | ||
| 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. | |
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 | ||
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 | | |
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). | |
| |||
| |||
29 | Measure piston projection | ||
| |||
| |||
30 | Install oil pump | ||
31 | Install cylinder heads | On model 613.367 | |
On model 613.368 | |||
32 | Installing oil pan | ||
33 | Pour in engine oil | ||
| Engine - oil and filter change | On model 613.367 | |
| Engine - oil and filter change | On model 613.368 | |
34 | Install lower engine-compartment encapsulation panel | ||
35 | Lower vehicle | ||
36 | Close maintenance flaps | - engine compartment flap at rear, - interior compartment flap above engine. |
Test and setting values for pistons
Number | Designation | Engine | Engine | |||
BE03.10-N-1005-02I | Piston projection at TDC relative to contact face of crankcase | mm | 0.224...0.715 | 0.224...0.715 | ||
Connecting rod
Number | Designation | Engine 457.941/ | Engine 457.944 | ||
BA03.10-N-1001-01H | Bolt of conrod bearing cap to conrod | 1st stage | NM | 100 | 100 |
2nd stage | ° | 90 | 90 | ||
000 589 64 21 00
Dial gage
Torque wrench
Retaining strap
Dial gage holder
000 589 38 31 00
001 589 53 21 00
343 589 00 40 00