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

ENGINES 604, 605, 606 

Fig 1: Identifying Piston Components (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Piston Components (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
1.1	Remove engine	Models 463 with engine 606.964	AR01.10-P-2400GG
2	Remove cylinder head	Models 124, 140, 202, 210	AR01.30-P-5800HA
		Models 463 with engine 606.964	AR01.30-P-5800GG
3	Remove oil pan	Engines 604, 605 in model 124 Engine 604, 605 in model 202	AR01.45-P-7500HA
		Engines 605, 606 in model 210 Engine 606.961 im Typ 140	AR01.45-P-7500C
		Engine 604 in model 210	AR01.45-P-7500D
		Engine 606.964 in model 210	AR01.45-P-7500GG
4	Remove oil pump		AR18.10-P-6020HA
5	Remove oil deflector plate
6	Unscrew connecting rod bearing cap (1)	Connecting rod (2) and connecting rod bearing cap (1) are marked together (arrow).
7	Remove connecting rod (2) with piston (4) by lifting up and out	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.
8	Use a screwdriver to press out piston pin retainer (5)	Do not damage piston. Use a clean cloth as a base
9	Press out gudgeon pin (6)
	Installing
10	Oil gudgeon pin (6) and connecting rod bush
11	Assemble piston (4) and connecting rod (2)	Install piston with arrow pointing in direction of travel. The marking and the retaining lugs 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)	Do not mix up top and bottom connecting rod bearing shells
15	Fit on tensioning strap (7) for piston rings and tension		Figure
16	Install piston (4) with arrow pointing in direction of travel
17	Inspect connecting rod bolts		AR03.10-P-6111-01A  *BE03.10-P-1001-03A
18	Screw on connecting rod bearing cap (1)	Bolt connecting rod bearing cap (1) and connecting rod (2) to each other with the markings (arrows) lined up.
			*BA03.10-P-1001-01B
19	Rotate crankshaft and inspect clearance		AR03.10-P-6111-02A
20	Install oil deflector plate		AR03.10-P-7021-01A
21	Install oil pump		AR18.10-P-6020HA
22	Installing oil pan	Engines 604, 605 in model 124 Engine 604, 605 in model 202	AR01.45-P-7500HA
		Engines 605, 606 in model 210 Engine 606.961 im Typ 140	AR01.45-P-7500C
		Engine 604 in model 210	AR01.45-P-7500D
		Engine 606.964 in model 463	AR01.45-P-7500GG
23	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-P-7041-01A
			*BE03.10-P-1001-02B  *BE03.10-P-1002-02B
24	Install cylinder head	Models 124, 140, 202, 210	AR01.30-P-5800HA
		Model 463 with engine 606.964	AR01.30-P-5800GG
25.1	Install engine	Model 463 with engine 606.964	AR01.10-P-2400GG

Test values for pistons

Number	Designation			Engine 604.910/912	Engine 604.915/917
BE03.10-P-1001-02B	Piston projection (a) with new crankcase		mm	0.735...0.965	0.785...1.015
		See picture in		AR03.10-P-7041-01A	AR03.10-P-7041-01A
BE03.10-P-1002-02B	Piston projection (a) with machined crankcase		mm	0.835...1.015	0.985...1.215
		See picture in		AR03.10-P-7041-01A	AR03.10-P-7041-01A

Test values for pistons

Number	Designation			Engines 605.91/96	Engine 606.91/96
BE03.10-P-1001-02B	Piston projection (a) with new crankcase		mm	0.785...1.015	0.785...1.015
		See picture in		AR03.10-P-7041-01A	AR03.10-P-7041-01A
BE03.10-P-1002-02B	Piston projection (a) with machined crankcase		mm	0.985...1.215	0.985...1.215
		See picture in		AR03.10-P-7041-01A	AR03.10-P-7041-01A

Test data for connecting rod bolts

Number	Designation				Engine 604, 605, 606
BE03.10-P-1001-03A	Connecting rod bolts	Thread dia. ø		M	9x1
		Shank length	when new	mm	51.7...52.3
			max.	mm	52.9
		Part no.			111.038 00 71

Connecting rod

Number	Designation			Engine 604, 605, 606
BA03.10-P-1001-01B	Connecting rod bolt (stretch shank)	Stage 1	Nm	40
		Stage 2	° ∠	90

Fig 3: Identifying Retaining Strap (000 589 04 14 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.