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Removing / installing a piston - AR03.10-P-7021AW

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ENGINES 601, 602, 603 (except, 602.98) 

Fig 1: Identifying Piston Remove / Install Components (1 Of 2)
G05438226Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Piston Remove / Install Components (2 Of 2)
G05438227Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Remove    
1 Remove engine Models 124, 126, 140, 201, 202 AR01.10-P-2400HX
Model 124 4MATIC AR01.10-P-2400HY
2 Remove cylinder head   AR01.30-P-5800HX
3 Remove oil pan Engine 603.913/963 in model 124 with 4MATIC AR01.45-P-7500HX
Engine 603.971 in model 140 AR01.45-P-7500HY
Engines 601, 602 in MODEL 124, 201 AR01.45-P-7500HZ
Engine 603 (except 603.913/963) in model 124  
Engine 603 in model 126  
Engine 601 in model 202 AR01.45-P-7500HA
4 Remove oil pump   ra18006010210x
5 Unscrew connecting rod bearing cap (1) IMPORTANT Connecting rod (2) and connecting rod bearing cap (1) are marked together (arrow).  
6 Remove connecting rod (2) with piston (4) by lifting up and out IMPORTANT If the pistons are worn, the direction of travel of arrows may no longer be visible because of carbon deposits. For this reason, remove carbon deposits to render direction of travel arrow visible.  
7 Use a screwdriver to press out piston pin retainer (5) NOTES Do not damage piston. Use a clean cloth as a base  
8 Press out piston pin (6) and take off piston (4)    
INSTALLING Installing     
9 Inspect connecting rod bush inner diameter if excessive wear present ↓  
Installing a new connecting rod bush AR03.10-P-6111-03AW 
  *BE03.10-P-1006-01C 
  *BE03.10-P-1007-01C 
  *BE03.10-P-1008-01C 
  *BE03.10-P-1009-01C 
  *BE03.10-P-1010-01C 
10 Oil gudgeon pin (6) and connecting rod bush    
11 Assemble piston (4) and connecting rod (2) NOTES Install piston with arrow in direction of travel.
IMPORTANT The marking and the retaining grooves in the connecting rod are located on the left (at the inlet side).		  
12 Push in piston pin (6) by hand.    
13 Insert piston pin retainer (5) into the groove (arrow) on the piston.    
14 Oil cleaned cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons (4)    
15 Fit on tensioning strap (7) for piston rings and tension SPECIAL TOOL Fig 5
16 Install piston (4) with arrow pointing in direction of travel IMPORTANT Re-install piston at the same point.
Pay attention to piston assignment		  
17 Inspect connecting rod bolts Replace, if necessary. AR03.10-P-6111-01AW 
  *BE03.10-P-1001-03C 
  *BE03.10-P-1002-03C 
18 Install connecting rod bearing cap (1) IMPORTANT Install connecting rod bearing cap (1) and connecting rod (2) with the markings (arrows) pointing to each other.  
19 Tightening connecting rod screws   AR03.10-P-6111-02AW 
TORQUE SPECIFICATION *BA03.10-P-1001-01C 
TORQUE SPECIFICATION *BA03.10-P-1002-01C 
20 Rotate crankshaft and inspect clearance    
21 Install oil pump   ra18006010210x
22 Installing oil pan Engine 603.913/963 in model 124 AR01.45-P-7500HX
Engine 603.971 in model 140 AR01.45-P-7500HY
Engines 601, 602 in model 124, 201 AR01.45-P-7500HZ
  Engine 603 (except 603.913/963) in model 124
  Engine 603 in model 126
Engine 601 in model 202 AR01.45-P-7500HA
23 Measure piston projection IMPORTANT Install cylinder head gasket of standard thickness or cylinder head gasket of repair thickness (1.85 mm thick) depending on piston projection AR03.10-P-7041-01AW 
  *BE03.10-P-1001-02B 
  *BE03.10-P-1002-02B 
SPECIAL TOOL Fig 3
SPECIAL TOOL Fig 4
24 Install cylinder head   AR01.30-P-5800HX
25 Install engine Models 124, 126, 140, 201, 202 AR01.10-P-2400HX
Model 124 4MATIC AR01.10-P-2400HY
INSPECTION DATA FOR CONNECTING ROD

Number Designation Engine 601.921 USA ONLY up to 09/84 Engine 601.921 USA ONLY as of 10/84
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 27.018...27.024 26.012...26.018
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 29.560...29.600 28.575...28.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore Ø (d1) mm 29.500...29.521 28.500...28.521
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
INSPECTION DATA FOR CONNECTING ROD

Number Designation Engine 601 up to 09/84 except 601.921 USA ONLY Engine 601 as of 10/84 except 601.921 USA ONLY , engine 602.91, 603.91
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 27.018...27.024 26.012...26.018
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 29.560...29.600 28.575...28.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore Ø (d1) mm 29.500...29.521 28.500...28.521
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
INSPECTION DATA FOR CONNECTING ROD

Number Designation Engines 602.96, 603.96 Engine 603.97
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 28.012...28.024 28.018...28.024
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 30.575...30.600 30.575...30.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore Ø (d1) mm 30.500...30.525 30.500...30.525
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
TEST DATA FOR CONNECTING ROD BOLTS

Number Designation Engines 601, 602 except 602.98, 603 except 603.970 up to 11/90 603.970 up to 8/90 Engine 601, 602 except 602.98, 603 except 603.970 as of 12/90 - 10/92 603.970 as of 9/90 - 10/92 Engines 601, 602 except 602.98, 603 as of 11/92
BE03.10-P-1001-03C Connecting rod bolt (straight stretch shank) Thread dia.Ø   M - 9X1 9X1
Length (L) when new mm - 51.7 51.7
max. mm - 52.9 52.9
Stretch shank diameter New mm - 8.5 -
minimum mm - 8.2 -
  See picture in   - AR03.10-P-6111-01AW  AR03.10-P-6111-01AW 
BE03.10-P-1002-03C Connecting rod bolt (stretch bolt) Thread dia.Ø   M 9X1 - -
Length (L) when new mm 51.7 - -
max. mm - - -
Stretch shank diameter New mm 7.3 - -
minimum mm 7.1 - -
  See picture in   AR03.10-P-6111-01AW  - -
TEST VALUES FOR PISTONS

Number Designation Engine 601, 602 except 602.98, 603
BE03.10-P-1001-02B Piston projection (a) with new crankcase   mm 0.74...0.96
See picture in   -
BE03.10-P-1002-02B Piston projection (a) with machined crankcase   mm 0.96...1.16
See picture in   -
TORQUE SPECIFICATION CONNECTING ROD

Number Designation Engines 601, 602 except 602.98, 603 except 603.970 up to 11/90 603.970 up to 8/90 Engines 601, 602 except 602.98, 603 except 603.970 as of 12/90 - 10/92 603.970 as of 9/90 - 10/92 Engines 601, 602 except 602.98, 603 as of 11/92
BA03.10-P-1001-01C Connecting rod bolt (stretch shank) Stage 1 new Nm - 45 40
used Nm - 40 -
Stage 2   ∠ ° - 90 90
See picture in     - AR03.10-P-6111-01AW  AR03.10-P-6111-01AW 
BA03.10-P-1002-01C Connecting rod bolt (stretch bolt) Stage 1   Nm 30 - -
Stage 2   ∠ ° 90 - -
See picture in     AR03.10-P-6111-01AW     
Fig 3: Identifying Dial Indicator (001 589 53 21 00)
G05438228Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Dial Indicator Holder (343 589 00 40 00)
G05438229Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Retaining Strap (000 589 04 14 00)
G05438230Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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