Piston removal and installation - AR03.10-P-7021GZ: Notes

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ENGINE 113.964 in MODEL 164.175

Fig 1: Identifying Piston Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
	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 below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
1	Remove engine		AR01.10-P-2400GZ
2	Detach automatic transmission from engine		AR27.10-P-0500GZ
3	Remove oil pan top section		AR01.45-P-7500GZ
4	Take off cylinder head	Remove intake manifold with complete wiring harness during this step.	AR01.30-P-5800GZ
5	Remove oil pump	For this step, push back chain tensioner and take off chain.	AR18.10-P-6020GZ
6	Remove connecting rod bearing cap (5)	For this step, mark conrod (4) and connecting rod bearing cap (5) on one side relative to each other.
7	Remove the connecting rod (4) with the pistons (3) from the crankcase in the direction of the cylinder head	Mark the pistons according to the cylinder bores. 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 the circlip (1) from the piston pin (2)	Do not damage piston (3). Place a clean cloth underneath.
9	Push out the piston pin (2) from the piston (3)
	Install
10	Assign piston (3) to cylinder bore		AR03.10-P-7021-02BV
		Cylinder dia.	*BE01.40-P-1001-01F
		Piston diameter	*BE03.10-P-1001-02D
		Piston clearance	*BE03.10-P-1002-02D
11	Oil piston pin (2) and conrod bush
12	Assemble piston (3) and conrod (4)	Install piston (3) with arrow in direction of travel.
13	Push in piston pin (2) by hand
14	Insert circlip (1) for piston pin (2) into the groove on the piston (3)	Do not damage piston (3). Place a clean cloth underneath.
15	Oil the cleaned parts (cylinder bores, connecting rod bearing journal, connecting rod bearing shells and pistons)
16	Fit the tensioning strap (10) and tighten	Piston ring gaps must be offset 120°.
		Tensioning strap	Figure
17	Install piston (3) with arrow pointing in direction of travel	Rotate crankshaft sufficiently so that the connecting rod (4) is not touching the connecting rod journal when the piston is inserted into the cylinder bore.
18	Inspect the conrod bolts (6)		AR03.10-P-6111-01VT
		Conrod bolts	*BE03.10-P-1001-03A
19	Install the conrod bearings and fit the conrod bearing cap (5)	The connecting rod bearing shell (7) with the oil drilling (arrow) must be installed in the connecting rod (4) otherwise the piston pins (2) will not be greased. The anti-twist lock (8) on the connecting rod bearing shell (7) must be located in the grooves (9) of the connecting rods (4) and of the connecting rod bearing cap (5). connecting rod (4) and connecting rod bearing cap (5) are cracked (arrow). They must not be installed the wrong way round!	AR03.10-P-6111-06VT
		Connecting rod bearing play	*BE03.20-P-1002-04E
20	Tighten conrod bolts (6)		AR03.10-P-6111-02VT
			*BA03.10-P-1001-01E
		External Torx set	Figure
21	Rotate crankshaft	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.	AR18.10-P-6020GZ
23	Fit the cylinder head		AR01.30-P-5800GZ
24	Fit the oil pan top section		AR01.45-P-7500GZ
25	Fit the automatic transmission		AR27.10-P-0500GZ
26	Install engine		AR01.10-P-2400GZ

TEST DATA FOR CONROD BOLTS

Number	Designation				Engine 112 except 112.951/976, engine 113.94/96/971/980/981/982/984/986
BE03.10-P-1001-03A	Conrod bolts	Thread dia. Ø		M	8X1
		Shank length	When new	mm	47
			Max.	mm	47.6
			Part no.		-

TEST VALUES FOR CYLINDER BORE

Number	Designation			Engine 113.960/961/ 962/963/964/ 965/967/968/ 971/980/981/ 982/984/987/ 988/989/990/ 991/992/993/ 995
BE01.40-P-1001-01F	Cylinder dia.	Standard marking X	mm	97.000 to 97.015
		Auxiliary stage marking ⓧ	mm	97.050 to 97.065
		Repair size	mm	97.250 to 97.265

TEST VALUES FOR PISTONS

Number	Designation			Engine 113.960/ 961/962/963/ 964/965/967/ 968/971/980/ 981/982/984
BE03.10-P-1001-02D	Piston dia. Ø	Standard marking X	mm	96.972 to 97.000
		Auxiliary stage marking ⓧ	mm	97.022 to 97.050
		Repair size	mm	97.222 to 97.250
BE03.10-P-1002-02D	Piston clearance	Standard marking X	mm	≤ 0.043
		Auxiliary stage marking ⓧ	mm	≤ 0.043
		Repair size	mm	≤ 0.043

INSPECTION DATA OF CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 112 except 112.951/976, Engine 113.940/941/942/943/944/948/960/961/963/964/965/966/967/968/971/980/981/984/986
BE03.20-P-1002-04E	Connecting rod bearing play	Radial when new	mm	0.022...0.067

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)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying External Torx Set (001 589 76 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.