Removing the piston with connecting rod

Precondition

Remove and install front axle complete with engine and transmission.
Engine oil has been drained

WARNING: Hot fluids.
Risk of scalding!

Conduct all work in the vehicle wearing appropriate personal protective equipment only.

WARNING: Car may slip off the vehicle hoist where components are supported.
Danger! Immobilization period-threatening injuries!

Secure the vehicle hoist against lowering and lifting.
Make sure that the vehicle does not lift off the mounting plates on the vehicle lift.

WARNING: Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly.
Danger! Immobilization period-threatening injuries!

Observe safety instructions on raising the vehicle using a vehicle hoist.
For additional information see: 00... RAISING THE VEHICLE USING A VEHICLE LIFT .

WARNING: Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!

Ensure there is a specific weight compensation on the car.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Preliminary work

Refer to REMOVING THE ENGINE FROM THE LIFTING TABLE .
Refer to MOUNTING THE ENGINE TO THE ENGINE SUPPORT BRACKET .
Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
Refer to REMOVING THE LEFT AND RIGHT CHARGE AIR COOLER (ENGINE REMOVED) .
Refer to RELEASING THE UPPER HEAT SHIELD .
Refer to REMOVING DRIVE BELT .
Refer to REMOVING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
Refer to REMOVING THE VIBRATION DAMPER .
Refer to REMOVING FLYWHEEL .
Refer to REMOVING THE COOLANT PUMP .
Refer to REMOVING THE BELT TENSIONER .
Refer to REMOVING THE ALTERNATOR .
Refer to PREPARING SPECIAL TOOL (8.5 MM DIAMETER) .
Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 2 .
Refer to REMOVING LEFT MOUNT .
Refer to REMOVING RIGHT MOUNT .
Refer to REMOVING THE LEFT AND RIGHT EXHAUST TURBOCHARGER .
Refer to REMOVING HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
Refer to REMOVING HEAT SHIELD OF CYLINDER HEAD COVER OF CYLINDERS 5 TO 8 .
Refer to REMOVING BOTH EXHAUST MANIFOLDS .
Refer to REMOVING FRONT HEAT SHIELD .
Refer to REMOVING HEAT SHIELD AT BOTTOM .
Refer to REMOVING FUEL DELIVERY LINE .
Refer to REMOVING IGNITION COIL OF CYLINDER BANK 1 .
Refer to REMOVING IGNITION COIL OF CYLINDER BANK 1 .
Refer to REMOVING HIGH PRESSURE RAIL AT CYLINDER BANK 1 .
Refer to DISCONNECTING THE PLUG CONNECTIONS OF THE INJECTORS OF CYLINDER BANK 1 .
Refer to REMOVING INJECTORS .
Refer to REMOVING VACUUM PUMP .
Removing conduit from bank 1.

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- Loosen screws (1).
- Slide conduit (2) downwards.
Refer to REMOVING IGNITION COIL OF CYLINDER BANK 2 .
Refer to REMOVING THE RIGHT HIGH PRESSURE PUMP .
Refer to REMOVING RAIL FROM BANK 2 .
Refer to DISCONNECTING PLUG CONNECTIONS OF THE INJECTORS OF CYLINDER BANK 2 .
Refer to REMOVING INJECTORS .
Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
Refer to REMOVING LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
Refer to REMOVING LEFT HIGH PRESSURE PUMP .
Refer to REMOVING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
Removing conduit from bank 1.

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- Loosen screws (1).
- Slide conduit (2) downwards.
Refer to REMOVING THE TANK VENTILATION LINE OF CYLINDER BANK 1 PARTIALLY .
Refer to REMOVING ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
Refer to REMOVING THE WIRING HARNESS FROM THE CYLINDER BANK 2 .
Refer to REMOVING RIGHT CYLINDER HEAD COVER .
Refer to REMOVING LEFT CYLINDER HEAD COVER .
Refer to CHECKING THE VANOS ADJUSTER OF CYLINDER BANK 1 .
Refer to RELIEVING THE CHAIN TENSIONER AT CYLINDER BANK 1 FOR CHECKING OR SETTING THE VALVE TIMINGS .
Refer to REMOVING HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 1 .
Refer to PRELOADING THE TIMING CHAIN OF CYLINDER BANK 1 .
Refer to SECURING THE ENGINE IN INSTALLATION POSITION AT CYLINDER 1 .
Refer to INSTALLING THE SPECIAL TOOL TO SECURING THE CAMSHAFTS OF CYLINDER BANK 1 .
Refer to REMOVING BOTH RIGHT VANOS ADJUSTERS .
Refer to REMOVING SPECIAL TOOL FOR FIXING CAMSHAFTS ON BANK 1 .
Refer to REMOVING THE SEALING CAP ON THE CYLINDER HEAD OF THE CYLINDER BANK 2 .
Refer to MOVING THE CRANKSHAFT INTO THE INSTALLATION POSITION OF CYLINDER BANK 1 .
Refer to CHECKING THE VANOS ADJUSTER OF CYLINDER BANK 2 .
Refer to RELAXING CHAIN TENSIONER ON BANK 2 FOR CHECKING OR SETTING TIMING .
Refer to REMOVING HYDRAULIC CHAIN TENSIONER OF CYLINDER BANK 2 .
Refer to PRELOADING THE TIMING CHAIN OF CYLINDER BANK 2 .
Refer to SECURING THE ENGINE IN INSTALLATION POSITION AT CYLINDER 1 .
Refer to INSTALLING THE SPECIAL TOOL TO SECURING THE CAMSHAFTS OF CYLINDER BANK 2 .
Refer to REMOVING BOTH LEFT VANOS ADJUSTERS .
Refer to REMOVING RIGHT CYLINDER HEAD .
Refer to REMOVING LEFT CYLINDER HEAD .
Refer to REMOVING LOWERING OIL PAN SECTION .
Refer to REMOVING OIL PUMP .
Refer to RELEASING AIR CONDITIONING COMPRESSOR .
Refer to REMOVING THE RIGHT ENGINE MOUNTING HOLDER .
Refer to REMOVING FRONT AXLE DIFFERENTIAL .
Refer to REMOVING THE LEFT ENGINE SUPPORT BRACKET .
Refer to REMOVING UPPER OIL SUMP SECTION (ENGINE REMOVED) .

NOTE: TECHNICAL INFORMATION
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.

NOTE: The description is provided only at one component. The procedure is the same for all other components.

NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage.

Twist the crankshaft (2) into the position for disassembly.
Unscrew both connecting rod bolts (1) .
Remove the connecting rod bearing cap (3) with guide bearing shell.

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NOTE: TECHNICAL INFORMATION
For installation and dismantling of the connecting rods, it is essential for the crankshaft to be exactly in alignment with the cylinder bore.

Screw in the special tools 2 249 164 hand-tight into the threaded connection of the connecting rod bolts (1) .
Press out the piston with the connecting rod using special tool 2 249 164 .

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

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Remove the piston and connecting rod in an upward direction.
Lever the connecting rod bearing shell (1) out of the connecting rod bearing cap (see arrows).

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Lever the connecting rod bearing (1) out of the connecting rod (see arrows).

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NOTE: The description is provided only at one component. The procedure is the same for all other components.

Measure the cylinder path.

TECHNICAL DATA SPECIFICATION

Engine in general, bore
Tightening Torque	89 UNIT

TECHNICAL DATA SPECIFICATION

Piston installation clearance (piston new)
Piston installation clearance (piston new)	0.003... 0.023 mm

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TECHNICAL DATA SPECIFICATION

Permissible total wear tolerance between piston and cylinder (engine operated)
Piston installation clearance (piston worn)	0.25 mm

Check

Position micrometer in area (A) and measure piston installation clearance transversely to piston pin.

TECHNICAL DATA SPECIFICATION

Piston diameter
Measure the piston diameter at distance (A) from the lower end of the piston skirt.	Distance (A) to the lower end of the piston skirt Nominal dimension of piston diameter	27 mm 88.987 ^+0.02_-0.02 mm
		27 mm 88.987 ^+0.02_-0.02 mm

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Result

» Piston does not correspond to the specifications.

Measure

Replace piston.

Remove upper and middle piston ring (1) with a piston ring pliers (2) .

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Remove oil scraper ring (2) (U-Flex) by hand over the piston skirt (1) .

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Check the arrangement of the piston rings.
Piston ring (1)

Piston ring (2)

Oil scraper ring (3)

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Clean the ring zone on the piston.
Insert piston ring (1) in the annular groove on the piston and check it with feeler gauge (2) .

TECHNICAL DATA SPECIFICATION

Piston ring 1st groove A
Side clearance.	0.02... 0.07 mm

TECHNICAL DATA SPECIFICATION

Piston ring 1st groove H
Annular groove height.	1.21... 1.24 mm

TECHNICAL DATA SPECIFICATION

Piston ring 2nd groove A
Side clearance.	0.015... 0.06 mm

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TECHNICAL DATA SPECIFICATION

Piston ring 2nd groove H
Annular groove height.	1.51... 1.53 mm

TECHNICAL DATA SPECIFICATION

Piston ring 3. Groove-A DSF ring
Side clearance without spiral expander.	0.02... 0.06 mm

TECHNICAL DATA SPECIFICATION

Piston ring 3rd groove H
Annular groove height.	2.01... 2.03 mm