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Piston removal and installation - AR03.10-P-7021GZA (ML350, ML550, GL450, GL550): Notes

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ENGINE 272, 273 in MODEL 164, 251 

Fig 1: Identifying Piston Components
G05257288Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Retaining Strap
G05257289Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES

18.10.05 Remove, install engine with front axle carrier, added Steps 2, 37  
Remove/install automatic transmission - added Steps 3, 36  
Remove, install engine with front axle carrier, added Steps 4, 35  
REMOVING Removing    
1 Remove engine with front axle carrier   AR01.10-P-2500GZA
2 Remove automatic transmission Model 164 AR27.10-P-0500GZA
    Model 251 AR27.10-P-0500RTA
3 Detach engine from front axle carrier   AR01.10-P-2510GZA
4 Mount engine onto assembly stand    
5 Remove oil pan bottom section   AR01.45-P-7555GZA
6 Remove oil pan   AR01.45-P-7500GZA
7 Remove oil pump   AR18.10-P-6020GZA
8 Remove oil baffle from crankcase    
9 Remove resonance intake manifold   AR09.20-P-1961GZA
10 Remove right cylinder head and left cylinder head Right cylinder head AR01.30-P-5780GZA
    Left cylinder head AR01.30-P-5770GZA
11 Mark connecting rod (2) and connecting rod bearing cap (1) at one side with markings (11) NOTES Connecting rod (2) and connecting rod bearing cap (1) are cracked. They must not be mixed up amongst each other or installed laterally inverted as the dimensional accuracy would no longer be there!  
12 Remove connecting rod bearing cap (1)    
13 Remove connecting rod (2) with pistons (3) from crankcase in the direction of cylinder head IMPORTANT Mark the pistons (3) according to the cylinder bores.
IMPORTANT If pistons are used (3), the arrows indicating the driving direction and the marking of the pistons (3) may no longer be visible because of carbon deposits. For this reason, remove carbon deposits from pistons (3). If arrows indicating the driving direction on pistons (3) are no longer recognizable then these must be newly marked.		  
14 Remove circlip (4) from piston pin (5) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
15 Push out piston pin (5) from piston (3)    
INSTALLING Install     
16 Assign piston (3) to cylinder bore   AR03.10-P-7021-02VA 
    Cylinder diameter *BE01.40-P-1001-01I 
    Piston diameter *BE03.10-P-1001-02D 
    Piston clearance *BE03.10-P-1002-02D 
17 Lubricate piston pin (5) and connecting rod bush    
18 Align piston (3) and connecting rod (2) IMPORTANT Install piston (3) with arrow in direction of travel.  
19 Push piston pin (5) by hand into piston (3)    
20 Insert circlip (4) for piston pin (5) into groove on piston (3) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
21 Oil cleaned cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons (3)    
22 Place tensioning strap (6) on piston (3) and tension IMPORTANT Piston ring gaps must be offset 120°.  
    SPECIAL TOOL Figure
23 Install piston (3) in direction of travel IMPORTANT Observe arrow (in direction of travel) on piston (3).
IMPORTANT Rotate crankshaft so that connecting rod (2) is not touching connecting rod journal when inserting the piston (3) into the cylinder bore!		  
24 Inspect connecting rod bolts (7)   AR03.10-P-6111-01VA 
    Thread diameter and shank length *BE03.10-P-1001-03A 
25 Install connecting rod bearings and fit connecting rod bearing cap (1) Engine 272 AR03.10-P-6111-06VA 
    Engine 273
IMPORTANT The anti-twist lock (8) on connecting rod bearing shell (10) must be located in grooves (9) of connecting rods (2) and of connecting rod bearing cap (1).
NOTES Connecting rod (2) and connecting rod bearing cap (1) are cracked. They must not be mixed up amongst each other or installed laterally inverted as the dimensional accuracy would no longer be there!		 AR03.10-P-6111-08SX 
    Connecting rod bearing play *BE03.20-P-1002-04E 
26 Tighten connecting rod bolts (7)   AR03.10-P-6111-02VA 
    TORQUE SPECIFICATION *BA03.10-P-1001-01E 
27 Crank crankshaft by hand and check for unobstructed movement of crankshaft assembly    
28 Install oil deflector plate TORQUE SPECIFICATION *BA18.10-P-1006-01B 
29 Install oil pump   AR18.10-P-6020GZA
30 Installing oil pan   AR01.45-P-7500GZA
31 Install oil pan bottom section   AR01.45-P-7555GZA
32 Install left cylinder head and right cylinder head Right cylinder head AR01.30-P-5780GZA
    Left cylinder head AR01.30-P-5770GZA
33 Install resonance intake manifold   AR09.20-P-1961GZA
34 Remove engine from assembly stand    
35 Attach engine to front axle carrier   AR01.10-P-2510GZA
36 Fit automatic transmission Model 164 AR27.10-P-0500GZA
    Model 251 AR27.10-P-0500RTA
37 Install engine with front axle carrier   AR01.10-P-2500GZA
CHECK VALUES FOR CONNECTING ROD BOLTS

Number Designation Engine 272 Engine 273
BE03.10-P-1001-03A Connecting rod bolts Thread Ø Ø   M 8x1 8x1
Shank length when new mm 39.5 39.5
  max. mm 40.5 40.5
  Part no.   - -
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 272.91/92/94 Engine 272.96/97/98/99
BE01.40-P-1001-01I Cylinder Ø Stage X mm 88.000 to 88.015 92.900 to 92.915
Stage ⓧ mm 88.100 to 88.115 93.000 to 93.015
Repair size mm 88.250 to 88.265 93.150 to 93.165
CHECK VALUES FOR CYLINDER BORE

Number Designation Engine 273.92 Engine 273.96
BE01.40-P-1001-01I Cylinder Ø Stage X mm 92.900 to 92.915 98.000 to 98.015
Stage ⓧ mm 93.000 to 93.015 98.100 to 98.115
Repair size mm 93.150 to 93.165 98.250 to 98.265
CHECK VALUES FOR PISTONS

Number Designation Engine 272.91/92/94/95 Engine 272.96/97/98/99
BE03.10-P-1001-02D Piston Ø Standard identification X mm 87.973...88.003 92.863...92.897
Auxiliary size marking ⓧ mm 88.073...88.103 92.963...92.997
Repair size mm 88.223...88.253 93.113...93.147
BE03.10-P-1002-02D Piston clearance Standard identification X mm 0.003...0.042 0.003...0.052
Auxiliary size marking ⓧ mm 0.003...0.042 0.003...0.052
Repair size mm 0.003...0.042 0.003...0.052
CHECK VALUES FOR PISTONS

Number Designation Engine 273.92 Engine 273.96
BE03.10-P-1001-02D Piston Ø Standard identification X mm 92.863 to 92.897 97.973 to 98.007
Auxiliary size marking ⓧ mm 92.963 to 92.997 98.073 to 98.107
Repair size mm 93.113 to 93.147 98.223...98.257
BE03.10-P-1002-02D Piston clearance Standard identification X mm 0.003 to 0.052 0.007 to 0.042
Auxiliary size marking ⓧ mm 0.003 to 0.052 0.007 to 0.042
Repair size mm 0.003 to 0.052 0.007 to 0.042
CHECK VALUES FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 272 Engine 273
BE03.20-P-1002-04E Connecting rod bearing play radial when new mm 0.022...0.066 0.022...0.066
CONNECTING ROD

Number Designation Engine 272 Engine 273
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 20 25
Stage 3 ∠° 90 90
OIL PUMP

Number Designation Engine 272 Engine 273
BA18.10-P-1006-01B Bolt, oil baffle at crankcase Nm 9 9
Fig 3: Identifying Retaining Strap (000 589 04 14 00)
G05257290Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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