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

ENGINE 275 

Shown on piston for a crankshaft journal 

Fig 1: Identifying Piston Remove/Install Components - Shown On Piston Of A Crankshaft Journal (Engine 275)

	Removing
	Removal of piston on the left occurs (4b) analog to removal of piston on the right (4a)
1.1	Remove engine	Model 215, 220 except 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07 Model 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07	AR01.10-P-2400MC
1.2	Remove engine with front axle carrier	Model 216, 221	AR01.10-P-2500SZ
		Model 230	AR01.10-P-2500RC
2	Remove transmission	Model 216, 221	AR27.10-P-0500SZ
		Model 230	AR27.10-P-0500RC
3	Detach engine from front axle carrier	Model 216, 221	AR01.10-P-2510SX
		Model 230	AR01.10-P-2510RX
4	Mount engine onto assembly stand
5	Remove cylinder head	The right or the left cylinder head must be removed depending on the piston which should be removed.	AR01.30-P-5800M
6	Detach oil pan	Model 215, 220	AR01.45-P-7500L
		Model 216, 221	AR01.45-P-7500SZ
		Model 230	AR01.45-P-7500RA
7	Remove oil deflector plate
8	Remove connecting rod bearing cap (1)	Mark connecting rod (2) and connecting rod bearing cap relative to each other so that, when installing, the parts are not mixed up. Connecting rod (2) and connecting rod bearing caps are cracked. They must not be installed on the wrong side as the accuracy of fit is no longer given.
9	Mark connecting rod bearing shell and connecting rod bearing cap (1) to each other
10	Mark piston on the right (4a) and cylinder liner relative to each other	Do not mix up the pistons, as this can lead to engine damage.
11	Remove connecting rod (2) with piston on the right (4a)	Observe the identification arrow on the piston crown. On pistons which are used, the identification arrow of the pistons may no longer be visible because of carbon deposits. The carbonization must therefore be removed from the piston. If the identification arrow is no longer recognizable on the piston, the piston must be identified again.
12	Mark connecting rod bearing shell and connecting rod (2) to each other	Do not mix up the upper and lower connecting rod bearing shell as this can lead to engine damage.
13	Remove the circlip (5) from the piston pin (6)	Use a clean shop towel as a base so that the piston is not damaged.
14	Press out piston pin (6)	The connecting rod (2) is not marked so mark connecting rod (2) and piston relative to each other so that the connecting rod (2) can be reinstalled in its original installation position with the piston.
15	Inspect connecting rod (2) for blue discoloration, cross scores and notches.	Connecting rods with blue discoloration as a result of bearing damage, with transverse scores and notches must be replaced as this can lead to engine damage
	Install
16	Assigning a standard size piston to a cylinder bore		AR03.10-P-7021-02L
17	Oil piston pin (6) and connecting rod bush
18	Assemble right-hand side piston (4a) and connecting rod (2)	Installation:  When installing, ensure that connecting collar (broad side) (a) points in direction of crank web when fitted.
19	Push in piston pin (6) by hand
20	Insert circlip (5) for piston pin (6) into the groove on piston on the right (4a)	Use clean shop towels as a base so that the piston on the right side (4a) is not damaged.
21	Lubricate cleaned cylinder bore, connecting rod journal, connecting rod bearing shells and piston on the right (4a)
22	Fit on tensioning strap (7) for piston rings and tension	During installation of the piston, the piston ring end gap of the first piston ring (upper piston ring) on the right side (4a) points forward in the direction of travel and the remaining piston ring end gaps are each offset by 120°.
			Figure
23	Install piston on the right (4a) with marking arrow pointing in direction of front of vehicle	On order to avoid causing damage during installation, turn crankshaft until connecting rod (2) does not touch connecting rod journal when inserting the piston on the right (4a).
24	Check connecting rod bolts (3)		AR03.10-P-6111-01L
25	Insert connecting rod bearing shell into connecting rod (2) and connecting rod bearing cap (1)	According to the attached markings. Do not mix up top and bottom connecting rod bearing shells. The anti-twist locks of the connecting rod bearing shells must be located in the slots of the connecting rods (2) and in the slots of the connecting rod bearing caps (1).
26	Install connecting rod bearing cap (1)	Bolt connecting rod bearing cap (1) and connecting rod (2) to each other with the markings (arrows) lined up.	AR03.10-P-6111-02L
27	Install oil deflector plate		*BA01.40-P-1002-01I
28	Installing oil pan	Model 215, 220	AR01.45-P-7500L
		Model 216, 221	AR01.45-P-7500SZ
		Model 230	AR01.45-P-7500RA
29	Install cylinder head		AR01.30-P-5800M
30	Detach engine from engine assembly stand
31	Attach engine to front axle carrier	Model 216, 221	AR01.10-P-2510SX
		Model 230	AR01.10-P-2510RX
32	Mount transmission	Model 216, 221	AR27.10-P-0500SZ
		Model 230	AR27.10-P-0500RC
33.1	Install engine	Model 215, 220 except 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07 Model 220 with special protection version, code 979, light armoring, code Z04 or top protection, code Z07	AR01.10-P-2400MC
33.2	Install engine with front axle carrier	Model 216, 221	AR01.10-P-2500SZ
		Model 230	AR01.10-P-2500RC

CRANKCASE, TIMING CASE COVER, END COVER

Fig 2: Identifying Retaining Strap (000 589 04 14 00)