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Home >> Mercedes Benz >> 1996 >> E320 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Crank Assembly - Testing & Repair - 210 Chassis >> Testing & Repair >> Piston removal and installation - AR03.10-P-7021AV

Piston removal and installation - AR03.10-P-7021AV

ENGINE 112 

ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250 

ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254 

ENGINE 113.982 in MODEL 463.243/246 

ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230 

Shown on engine 112 

Fig 1: Identifying Piston Position
G04605652Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVING Removing    
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
1 Remove engine Model 463.206/ 209/ 232/ 233/ 240/ 241 AR01.10-P-2400CC
Model 463.244/ 245/ 247/ 248/ 249/ 250/ 254 AR01.10-P-2401GT
Model 463.243/ 246 AR01.10-P-2401MG
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-2400RVK
Model 220 without 4MATIC AR01.10-P-2400AB
Model 220 with 4MATIC AR01.10-P-2400IW
Model 210 with 4MATIC AR01.10-P-2400C
Model 129, 202, 208, 210 without 4MATIC AR01.10-P-2400CB
Model 203 without 4MATIC, 209 with engine 112 AR01.10-P-2400PV
Model 203 with 4MATIC AR01.10-P-2400PW
Model 209 with engine 113 AR01.10-P-2400Q
Models 211.061/065/070 AR01.10-P-2400TC
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
2.1 Remove automatic transmission from engine Model 463.206/ 209/ 232/ 233/ 240/ 241 AR27.10-P-0500BD
Model 463.243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254 AR27.10-P-0500GA
Model 230.475 AR27.10-P-0500R
Model 230.474  
Model 220 without 4MATIC AR27.10-P-0500I
Model 220 with 4MATIC AR27.10-P-0500IW
Models 129, 170, 202, 208, 210 AR27.10-P-0500B
Model 203 without 4MATIC, 209 with engines 112, 113 AR27.10-P-0500P
Model 203 with 4MATIC AR27.10-P-0500PW
Model 211.061/065/070 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
2.2 Remove manual transmission from engine Models 129, 202, 210 AR26.10-P-0020A
Models 203, 209 with engine 112 AR26.10-P-0020P
Model 211.061 AR26.10-P-0020T
Model 208 with transmission 716.662/622 AR26.10-P-0020E
Model 170, AR26.10-P-0020D
Model 208 with transmission 716.663  
3 Remove oil pan top section Model 463.206/ 209/ 232/ 233/ 240/ 241/ 243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254 AR01.45-P-7500FG
Model 230. AR01.45-P-7500R
Model 220 without 4MATIC AR01.45-P-7500I
Model 220 with 4MATIC AR01.45-P-7500IW
Model 210 with 4MATIC AR01.45-P-7500FA
Model 210 without 4MATIC AR01.45-P-7500F
Models 208, 202 AR01.45-P-7500FC
Model 203 without 4MATIC, 209 with engines 112, 113 AR01.45-P-7500PV
Model 203 with 4MATIC AR01.45-P-7500PW
Models 211.061/065/070 AR01.45-P-7500TV
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
4 Take off cylinder head IMPORTANT Remove intake manifold with complete wiring harness during this step.  
Model 463.206/ 209/ 232/ 233/ 240/ 241/ 243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254 Engine 112 in model 129 and engine 113 in model 129, 202, 208, 210 Engine 112 in AR01.30-P-5800GV
Model 170, 202, 208, 210, 220 and Engine 113 in AR01.30-P-5800B
Model 220, 230.474 /475 AR01.30-P-5800BA
Model 163 AR01.30-P-5800MV
Model 203, 209 with engine 112, 113 AR01.30-P-5800PV
Models 211.061/065/070  
5 Remove oil pump IMPORTANT For this step, push back chain tensioner and take off chain.  
All except 203, 209, 211.061/065/070, 220 without 4MATIC, 230.474 /475 AR18.10-P-6020B
Model 203 without 4MATIC, 209, 211.061/065/070 AR18.10-P-6020PV
Model 203 with 4MATIC, model 220 with 4MATIC AR18.10-P-6020PW
Model 230.474/475 AR18.10-P-6020R
6 Remove connecting rod bearing cap (5) IMPORTANT For this step, mark conrod (4) and connecting rod bearing cap (5) on one side relative to each other.  
7 Remove conrod (4) together with pistons (3) by lifting up and out IMPORTANT If pistons have been used (3), the arrows indicating the direction of the travel and the markings on the pistons may no longer be visible due to carbon deposits. For this reason, remove the carbon deposits from the pistons. If the arrows indicating direction of travel on the pistons are no longer recognizable, these must be re-marked.  
8 Remove circlip (1) of piston pin (2) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
9 Press out piston pin (2)    
INSTALLING Install     
10 Assign piston (3) to cylinder bore   AR03.10-P-7021-02BV 
11 Oil piston pin (2) and conrod bush    
12 Assemble piston (3) and conrod (4) IMPORTANT Install piston (3) with arrow in direction of travel.  
13 Push in piston pin (2) by hand    
14 Insert circlip (1) of piston pin (2) in the groove on piston (3) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
15 Oil the cleaned parts (cylinder bore, conrod bearing journal, conrod bearing shells and pistons)    
16 Fit the tensioning strap (10) and tighten IMPORTANT Piston ring gaps must be offset 120°. SPECIAL TOOL Tensioning strap Fig 2
17 Install piston (3) with arrow pointing in direction of travel IMPORTANT Rotate crankshaft sufficiently so that the connecting rod does not touch the connecting rod journal when the piston is pushed into the cylinder bore.  
18 Inspect the conrod bolts (6) Thread and shank length AR03.10-P-6111-01BV 
*BE03.10-P-1001-03A 
19 Install the conrod bearings and fit the conrod bearing cap (5) NOTES The connecting rod bearing shell (7) with oil drilling (arrowed) must be mounted in the connecting rod, otherwise the piston pin (2) is not lubricated.
The anti-twist locks (8) of the connecting rod bearing shells (7) must be seated in the grooves (9) in the conrods (4) and connecting rod bearing caps (5).
The connecting rod and connecting rod bearing cap are cracked (broken) (arrowed). They must not be installed the wrong way round!		 AR03.10-P-6111-06AV 
20 Tighten conrod bolts (6) TORQUE SPECIFICATION AR03.10-P-6111-02BV 
*BA03.10-P-1001-01E 
21 Rotate crankshaft IMPORTANT To check for unobstructed movement.  
22 Install oil pump
  • Ensure that the oil return shutoff valve is correctly located.
  • Clean the oil pump strainer.
  • Fill the oil pump with engine oil before installing, so that oil is delivered at the initial startup.
  
All except 203, 209, 211.061/065/070, 220 without 4MATIC, 230.474 /475 AR18.10-P-6020B
Model 203 without 4MATIC, 209, 211.061/065/070 AR18.10-P-6020PV
Model 203 with 4MATIC, model 220 with 4MATIC AR18.10-P-6020PW
Model 230.474/475 AR18.10-P-6020R
23 Fit the cylinder head Model 463.206/ 209/ 232/ 233/ 240/ 241/ 243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254 AR01.30-P-5800GV
Engine 112 in model 129 and engine 113 in model 129, 202, 208, 210 AR01.30-P-5800B
Engine 112 in Model 170, 202, 208, 210, 220 and Engine 113 in Model 220, 230.474 /475 AR01.30-P-5800BA
Model 163 AR01.30-P-5800MV
Model 203, 209 with Engine 112, 113 AR01.30-P-5800PV
Models 211.061/065/070  
24 Fit the oil pan top section Model 463 AR01.45-P-7500FG
Model 230.474/475 AR01.45-P-7500R
Model 220 without 4MATIC AR01.45-P-7500I
Model 220 with 4MATIC AR01.45-P-7500IW
Model 210 with 4MATIC AR01.45-P-7500FA
Model 210 without 4MATIC AR01.45-P-7500F
Models 208, 202 AR01.45-P-7500FC
Model 203 without 4MATIC, 209 with engines 112, 113 AR01.45-P-7500PV
Model 203 with 4MATIC AR01.45-P-7500PW
Models 211.061/065/070 AR01.45-P-7500TV
Model 170 AR01.45-P-7500SV
Model 163 AR01.45-P-7500FB
Model 129 AR01.45-P-7500FD
25.1 Fit the automatic transmission Model 463.206/ 209/ 232/ 233/ 240/ 241 AR27.10-P-0500BD
Model 463.243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254 AR27.10-P-0500GA
Model 230.475 AR27.10-P-0500R
Model 230.474  
Model 220 without 4MATIC AR27.10-P-0500I
Model 220 with 4MATIC AR27.10-P-0500IW
Model 210, 208, 202,170. 129 AR27.10-P-0500B
Model 203 without 4MATIC, 209 with engines 112, 113 AR27.10-P-0500P
Model 203 with 4MATIC AR27.10-P-0500PW
Models 211.061/065/070 AR27.10-P-0500T
Model 163 AR27.10-P-0500GH
25.2 Fit on manual transmission Models 210,202, 129 AR26.10-P-0020A
Models 203, 209 with engine 112 AR26.10-P-0020P
Model 211.061 AR26.10-P-0020T
Model 208 with transmission 716.662/622 AR26.10-P-0020E
Model 170, AR26.10-P-0020A
Model 208 with transmission 716.663 AR26.10-P-0020D
26 Install engine Model 463.243/ 244/ 245/ 246/ 247/ 248/ 249/250/ 254 AR01.10-P-2400CC
Model 230.475 AR01.10-P-2400R
Model 230.474 AR01.10-P-2400RVK
Model 220 without 4MATIC AR01.10-P-2400AB
Model 220 with 4MATIC AR01.10-P-2400IW
Model 210 with 4MATIC AR01.10-P-2400C
Model 210 without 4MATIC, 208, 202, 129 AR01.10-P-2400CB
Model 203 without 4MATIC, 209 with engine 112 AR01.10-P-2400PV
Model 203 with 4MATIC AR01.10-P-2400PW
Model 209 with engine 113 AR01.10-P-2400Q
Model 211.061/065/070 AR01.10-P-2400TC
Model 170 AR01.10-P-2400SV
Model 163 AR01.10-P-2400CA
Test data for conrod bolts

Number Designation Engine 112 except 112.951/976, engine 113.94/96/971/ 980/981/982/ 984/986 Engine 113.992/995
BE03.10-P-1001-03A Conrod bolts Thread dia. ø   M 8x1 8x1
Shank length When new mm 47 42
  Max. mm 47.6 42.6
  Part no.   - -
TORQUE SPECIFICATION Connecting rod

Number Designation Engine 112,113
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 25
Stage 3 ∠° 90
Fig 2: Identifying Retaining Strap (000 589 04 14 00)
G04605653Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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