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Remove/install piston - AR03.10-P-7021MC

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ENGINES 275 

Fig 1: Identifying Piston Remove/Install Components
G10108142Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

15.8.08 Note for determination of valid measurement for a cylinder bore - added Step 1 AR03.10-P-7021-02L
REMOVING Removing     
IMPORTANT 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 IMPORTANT The right or the left cylinder head must be removed depending on the piston (4a, 4b) 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) IMPORTANT Mark connecting rod (2) and connecting rod bearing cap relative to each other so that, when installing, the parts are not mixed up.
NOTES Connecting rod (2) and connecting rod bearing cap 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 position of pistons (4a, 4b) and cylinder liner relative to each other NOTES Do not mix up the pistons, as this can lead to engine damage.  
11 Remove connecting rod (2) with pistons (4a, 4b) IMPORTANT Observe identification arrow on the piston crown. On pistons (4a, 4b) 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 NOTES 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) IMPORTANT Use clean shop towels as a base so that the piston on the pistons (4a, 4b) are not damaged.  
14 Press out piston pin (6) IMPORTANT The connecting rod (2) is not marked so mark connecting rod (2) and piston (4a, 4b) relative to each other so that connecting rod (2) can be reinstalled in its original installation position with piston (4a, 4b).  
15 Inspect connecting rods (2) for blue discoloration, cross scores and notches NOTES 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  
INSTALLING Install     
16 Assigning a standard dimension piston to a cylinder bore   AR03.10-P-7021-02L
*BE03.10-P-1003-02F 
*BE03.10-P-1004-02F 
*BE01.40-P-1001-01G 
17 Oil piston pin (6) and connecting rod bush    
18 Assemble piston (4a, 4b) and connecting rod (2) IMPORTANT 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 the piston (4a, 4b) NOTES Use a clean shop towel as a base so that the piston is not damaged.  
21 Lubricate cleaned cylinder bore, connecting rod journals, connecting rod bearing shells and pistons (4a, 4b)    
22 Fit on tensioning strap (7) for piston rings and tension IMPORTANT The piston ring end gap of piston ring 1 (upper ring) points to the front when the pistons (4a, 4b) are installed in the direction of travel while the remaining piston ring end gaps are offset each by 120°.  
SPECIAL TOOL Figure
23 Install piston (4a, 4b) with marking arrow pointing in direction of front of vehicle IMPORTANT In order to avoid causing damage during installation, turn crankshaft until connecting rod (2) does not touch connecting rod journal when inserting the piston.  
24 Check connecting rod bolts (3)   AR03.10-P-6111-01L
*BE03.10-P-1001-03A 
25 Insert connecting rod bearing shell into connecting rod (2) and connecting rod bearing cap (1) IMPORTANT According to the attached markings. Do not mix up top and bottom connecting rod bearing shells.
IMPORTANT The anti-twist locks of the connecting rod bearing shells must be located in the slots of the connecting rods and in the slots of the connecting rod bearing caps.		  
26 Install connecting rod bearing cap (1) IMPORTANT Bolt connecting rod bearing cap and connecting rod (2) to each other with the markings (arrows) lined up. AR03.10-P-6111-02L
TORQUE SPECIFICATION *BA03.10-P-1001-01E 
27 Install oil deflector plate TORQUE SPECIFICATION *BA01.40-P-1009-01C 
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 Install engine onto 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
TEST SPECIFICATIONS FOR PISTONS

Number Designation Engine 275.950/951/953/954, 285.950 Engine 275.98, 285.98
BE03.10-P-1003-02F Piston Ø Standard
Step markings X		 mm 81.970...82.008 82.563...82.575
Step marking ⓧ mm 82.020...82.058 82.613...82.625
BE03.10-P-1004-02F Piston clearance Default mm ≤0.04 -
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation Engine 137, 275, 285
BE03.10-P-1001-03A Connecting rod bolts Thread diameter M 7X1
Shank length New mm 38
  max. mm 38.4
TEST SPECIFICATIONS FOR CYLINDER BORE

Number Designation Engine 275.950/951/953/954, 285.950 Engine 275.98 285.98
BE01.40-P-1001-01G Cylinder dia. Standard marking X mm 82.000...82.015 82.600...82.615
Auxiliary stage marking ⓧ mm 82.050...82.065 82.650...82.665
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 137 Engine 275, 285
BA01.40-P-1009-01C Bolt, oil baffle to lower crankcase section Nm 8 8
CONNECTING ROD

Number Designation Engine 275, 285
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 15
Stage 3 ∠° 90
Fig 2: Identifying Tensioning Strap (000 589 04 14 00)
G09974053Courtesy of MERCEDES-BENZ USA
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