Remove/install a piston - AR03.10-P-7021AMG (ML63 AMG)

WARNING: This page does not describe the selected car, but rather 28 other vehicles, including the 2012 Mercedes-Benz GL550, 2012 Mercedes-Benz GL450, 2011 Mercedes-Benz ML63, 2011 Mercedes-Benz ML550, and 2011 Mercedes-Benz ML350. However, it is still accessible from the selected car via links, so may be relevant.

ENGINE 156

Fig 1: Identifying Piston Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Retaining Strap

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing
	Risk of death caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1.1	Remove engine with front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2500GZS
1.2	Remove engine	Engine 156.982 in model 209	AR01.10-P-2400QMG
		Engine 156.983 in model 211, 219	AR01.10-P-2400TMG
		Engine 156.984 in model 216, 221	AR01.10-P-2400SMG
2	Remove engine from front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2510GZS
3	Remove transmission from the engine
4	Mount engine onto assembly stand
5	Remove cylinder heads	Model 164, 251	AR01.30-P-5800GZS
		Model 209, 211, 219	AR01.30-P-5800TMG
		Model 216, 221	AR01.30-P-5800SMG
6	Detach oil pan bottom section	Model 164, 251	AR01.45-P-7555GZS
		Model 209, 211, 219	AR01.45-P-7555TMG
		Model 216, 221	AR01.45-P-7555SMG
7	Detach oil pan	Model 164, 251	AR01.45-P-7500GZS
		Model 209	AR01.45-P-7500QMG
		Model 211, 219	AR01.45-P-7500TMG
		Model 216, 221	AR01.45-P-7500SMG
8	Remove oil pump	Model 164, 251	AR18.10-P-6020GZS
		Model 209, 211, 219	AR18.10-P-6020TMG
		Model 216, 221	AR18.10-P-6020SMG
9	Detach engine support
10	Detach refrigerant compressor or compressor from cylinder crankcase and disconnect connector on oil temperature sensor		AR18.40-P-4123AMG
11	Remove vacuum reservoir from cylinder crankcase	On vehicles with vacuum reservoir at the cylinder crankcase
12	Unscrew bolts from cylinder crankcase lower section (Bedplate)
13	Mount crankshaft bracket on crankshaft	Crankshaft bracket	Fig 4
14	Place markings (11) on connecting rod (2) and connecting rod bearing cap (1) at one side	Connecting rod (2) and connecting rod bearing cap (1) are cracked (broken). They must not be swapped over with each other or installed the wrong way round. The dimensional accuracy will no longer be obtained otherwise.
15	Remove connecting rod bearing cap (1)
16	Remove connecting rod (2) with pistons (3) from crankcase in the direction of cylinder head	Mark the pistons according to the cylinder bores. If pistons are used, the direction of travel arrows and marking of pistons may be no longer visible because of carbon deposits. For this reason, remove carbon deposits from pistons. If arrows indicating direction of travel on the pistons are no longer recognizable, these must be re-marked.
17	Remove retaining ring (4) for piston pin (5)	Do not damage piston (3). Place clean rags underneath as a base.
18	Press piston pin (5) out of piston (3)
	Installing
19	Assign piston (3) to cylinder bore
20	Lubricate piston pin (5) and connecting rod small end
21	Align piston (3) and connecting rod (2)	Mount piston (3) with arrow in direction of travel (if present).
22	Push piston pins (5) into pistons (3)
23	Insert retaining ring (4) of piston pin (5) in piston (3)	Do not damage piston (3). Place clean rags underneath as a base.
24	Lubricate cleaned parts (cylinder bores, connecting rod journals, connecting rod bearing shells and piston (3))
25	Place tensioning strap (6) on piston (3) and tension it	Piston ring gaps must be offset 120°.
		Tensioning strap	Fig 3
26	Install piston (3) in direction of travel	Observe arrow (in direction of travel) on piston (3) (if present). Turn the crankshaft so that the connecting rod (2) is not at the connecting rod journal when piston (3) is inserted in the cylinder bore!
27	Install connecting rod bearings and connecting rod bearing cap (1)	The anti-twist locks (8) of connecting rod bearing shells (10) must be located in grooves (9) in connecting rod (2) and connecting rod bearing cap. Connecting rod (2) and connecting rod bearing cap are cracked (broken). They must not be mixed up amongst each other or installed laterally inverted as the dimensional accuracy would no longer be there.
28	Tighten connecting rod bolts (7)	The connecting rod bolts (7) must be replaced. The previously installed connecting rod bolts (7) must not be installed again. Through reuse loosening and associated engine damage can occur. Tighten connecting rod bolts (7) according to tightening specification.	AR03.10-P-6111-02AMG
		Connecting rod bearing cap on connecting rod	*BA03.10-P-1001-01Q
29	Turn crankshaft by hand and check for unobstructed movement of crank assembly
30	Remove crankshaft bracket on crankshaft	Crankshaft bracket	Fig 4
31	Remove sealant on cylinder crankcase and cylinder crankcase bottom section (Bedplate)	Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
32	Install cylinder crankcase lower section (Bedplate)		AR03.20-P-4351-05AMG
	Information on application of sealant to crankcase bottom section		AH01.40-P-1000-01AMG
		Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	*BA03.20-P-1001-01J
	Cylinder crankcase lower part to cylinder crankcase upper part		*BA03.20-P-1002-01J
	Loctite 5970 sealant		*BR00.45-Z-1013-01A
		Application gun	Fig 5
33	Replace rear crankshaft radial sealing ring	Model 164, 251	AR03.20-P-3063GZS
		Model 209, 211, 219	AR03.20-P-3063TMG
		Model 216, 221	AR03.20-P-3063SMG
34	Install vacuum reservoir
35	Mount engine support		*BA22.10-P-1001-02A
36	Mount the refrigerant compressor on the cylinder crankcase	Disconnect plug connection at oil temperature sensor.	AR18.40-P-4123AMG
37	Install oil pump	Model 164, 251	AR18.10-P-6020GZS
		Model 209, 211, 219	AR18.10-P-6020TMG
		Model 216, 221	AR18.10-P-6020SMG
38	Mount oil pan	Model 164, 251	AR01.45-P-7500GZS
		Model 209	AR01.45-P-7500QMG
		Model 211, 219	AR01.45-P-7500TMG
		Model 216, 221	AR01.45-P-7500SMG
39	Mount oil pan bottom section	Model 164	AR01.45-P-7555GZS
		Model 209, 211, 219	AR01.45-P-7555TMG
		Model 216, 221	AR01.45-P-7555SMG
40	Mount on cylinder heads	Model 164, 251	AR01.30-P-5800GZS
		Model 209, 211, 219	AR01.30-P-5800TMG
		Model 216, 221	AR01.30-P-5800SMG
41	Mount transmission to engine
42	Attach engine to front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2510GZS
43.1	Install engine with front axle carrier	Engine 156.980 in model 164, 251	AR01.10-P-2500GZS
43.2	Install engine	Engine 156.982 in model 209	AR01.10-P-2400QMG
		Engine 156.983 in model 211, 219	AR01.10-P-2400TMG
		Engine 156.984 in model 216, 221	AR01.10-P-2400SMG
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
44	Conduct engine test run and check engine for leaks

CONNECTING ROD

Number	Designation			Engine 156
BA03.10-P-1001-01Q	Connecting rod bearing cap on connecting rod	Stage 1	Nm	10
		Stage 2	Nm	40
		Stage 3	∠°	90

CRANKSHAFT BEARING CAP

Number	Designation				Engine 156
BA03.20-P-1001-01J	Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	M9	Stage 1	Nm	20
			Stage 2	Nm	32
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5		release
			Stage 6	Nm	20
		Stage 7		Nm	32
		Stage 8		∠°	90
		Stage 9		∠°	90
		M10	Stage 1	Nm	20
			Stage 2	Nm	40
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5	release
			Stage 6	Nm	20
			Stage 7	Nm	40
			Stage 8	∠°	90
			Stage 9	∠°	90

CRANKSHAFT BEARING CAP

Number	Designation				Engine 156
BA03.20-P-1002-01J	Cylinder crankcase lower part to cylinder crankcase upper part	M6	Stage 1	Nm	4
		M6	Stage 2	∠°	90
		M8	Stage 1	Nm	10
		M8	Stage 2	∠°	90

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation			Engine 156
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 1	Nm	20
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 2	∠°	90

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Crankshaft Bracket (156 589 00 40 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite 5970 sealant	A 003 989 98 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49 899268-0 Fax + 49 899101978 www.Loctite.de
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10