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

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ENGINE 157, 278 in MODEL 216, 221, 222, 231 

MODIFICATION NOTES

29.7.14 Document verification validity limited. Workstep validity created. Operation steps 2, 38  
Fig 1: Identifying Piston Remove/Install Components
G10108144Courtesy of MERCEDES-BENZ USA

Piston with travel direction arrow 

Fig 2: Identifying Piston Travel Direction Arrow
G10108145Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1 Remove engine with front axle carrier MODEL 222 with ENGINE 157, 278 AR01.10-P-2500LFB
MODEL 231 with ENGINE 157, 278 AR01.10-P-2500RKB
MODEL 216, 221 with ENGINE 157, 278 AR01.10-P-2500MMB
2 Detach transmission with torque converter ENGINE 157, 278 in MODEL 216, 221, 222, 231  
MODEL 231 with ENGINE 157 with TRANSMISSION 722.93
MODEL 231 with ENGINE 278 with TRANSMISSION 722.9		 AR27.10-P-0500RK
MODEL 222 with ENGINE 278 with TRANSMISSION 722.96 AR27.10-P-0500LHX
MODEL 222 with ENGINE 157 with TRANSMISSION 722.931
MODEL 222 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500LF
MODEL 216, 221 with ENGINE 157 with TRANSMISSION 722.9
with 4MATIC MODEL 216, 221 with ENGINE 278 with TRANSMISSION 722.9 with 4MATIC		 AR27.10-P-0500SYZ
MODEL 216.3, 221.0/1 with ENGINE 157 with TRANSMISSION 722.9
without 4MATIC MODEL 216.3, 221.0/1 with ENGINE 278 with TRANSMISSION 722.9 without 4MATIC		 AR27.10-P-0500SX
4 Remove both cylinder heads MODEL 231 with ENGINE 157, 278
Right cylinder head		 AR01.30-P-5780RKB
Right cylinder head MODEL 222 with ENGINE 157, 278 AR01.30-P-5780LFB
Right cylinder head MODEL 216, 221 with ENGINE 157, 278 AR01.30-P-5780MMB
Left cylinder head MODEL 231 with ENGINE 157, 278 AR01.30-P-5770RKB
Left cylinder head MODEL 222 with ENGINE 157, 278 AR01.30-P-5770LFB
Left cylinder head MODEL 216, 221 with ENGINE 157, 278 AR01.30-P-5770MMB
5 Remove oil pan MODEL 231 with ENGINE 157, 278 AR01.45-P-7500RKB
MODEL 222 with ENGINE 157, 278 AR01.45-P-7500LFB
MODEL 216, 221 with ENGINE 157, 278 AR01.45-P-7500MMB
6 Remove oil pump MODEL 231 with ENGINE 157, 278 AR18.10-P-6020RKB
MODEL 222 with ENGINE 157, 278 AR18.10-P-6020LFB
MODEL 216 with ENGINE 157, 278
MODEL 221 with ENGINE 157, 278		 AR18.10-P-6020MM
7 Mark installation position on the connecting rod bearing caps (1) and connecting rods (2) IMPORTANT The connecting rod (2) must be mounted on the same cylinder and in the same direction (arrow A).  
8 Remove connecting rod bolts (3)    
9 Remove connecting rod bearing cap (1)    
10 Remove connecting rod bearing shells (4) and mark if necessary relative to the associated connecting rod (2) and connecting rod bearing cap (1) IMPORTANT The connecting rod bearing shells (4) must be mounted on the same cylinder and in the same direction.  
11 Mark installation position and also direction of travel on piston (5) if necessary IMPORTANT The pistons (5) must be mounted on the same cylinder and in the same direction.
IMPORTANT If the travel direction arrows (picture) on the piston (5) are no longer recognizable due to soiling or carbonization, the pistons (5) must be cleaned. If no travel direction arrow can be recognized even after cleaning, the piston (5) itself must be marked with travel direction arrow (arrow D).		  
12 Remove piston (5) with connecting rod (2) upwards out of the crankcase    
13 Check piston rings (6a, 6b, 6c) for wear and damage    
IMPORTANT Notes on the assessment of pistons and piston rings   AH03.10-P-0001-04MM
14 Remove piston rings (6a, 6b, 6c) For replacement of the piston rings (6a, 6b, 6c) or the piston (5)  
AR03.10-P-7311MM 
15 Remove retaining ring (7) for piston pin (8)    
16 Mark piston pin (8) and connecting rod (2) relative to the piston (5) IMPORTANT The piston pin (8) and connecting rod (2) must be mounted on the same piston (5) and in the same direction.  
17 Press piston pin (8) out of piston (5)    
CLEAN Clean     
18 Clean all power unit components NOTES The power unit components must be absolutely free of soiling.
Engine damage may occur otherwise.		  
Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
19 Check all power unit components For damage or wear
↓
Replace the respective engine section.		  
20 Check cylinder barrel    
IMPORTANT General information on inspecting cylinder walls   AH01.00-P-0300-01MM
IMPORTANT General information on inspecting cylinder walls   AH01.00-P-0300-01VA
INSTALLING Install     
21 Assign piston (5) to the respective cylinder bore When replacing the pistons (5).  
AR03.10-P-7021-03MM
22 Lubricate piston pin (8) and connecting rod small end    
23 Align piston (5) and connecting rod (2) relative to each other IMPORTANT Note markings to restore the correct installation position.  
24 Press piston pin (8) by hand into piston (5)    
25 Insert retaining ring (7) of piston pin (8) into groove on piston (5) IMPORTANT The opening of the retaining ring (7) must point vertically in the direction of the piston crown (5a) (arrows B and C) after assembly.  
26 Mount piston rings (6a, 6b, 6c) For replacement of the piston rings (6a, 6b, 6c) or the piston (5)    
AR03.10-P-7311MM 
27 Lubricate cylinder bore, piston (5), connecting rod bearing shell (4) and connecting rod journal    
28 Tension piston rings (6a, 6b, 6c) onto the piston (5) using the tensioning strap IMPORTANT The pistons (5) must be installed with piston ring end gaps installed offset by 1200 degrees.  
SPECIAL TOOL Tensioning strap Figure
29 Install piston (5) in direction of travel IMPORTANT Note travel direction arrow or marking on piston (5).
IMPORTANT Rotate crankshaft so that connecting rod (2) is not touching any connecting rod on the connecting rod journal when inserting the piston (5) into cylinder bore.		  
30 Check connecting rod bolts (3)   AR03.10-P-6111-01MM
Connecting rod bolts *BE03.10-P-1001-03A 
31 Install connecting rod bearing shells (4) and put on connecting rod bearing cap (1)   AR03.10-P-6111-06MM
NOTES One must ensure that the anti-twist lock (b) for the connecting rod bearing shell (4) lies on the respective inner edge of the groove (a). The connecting rod bearing shells (4) will not sit in the middle otherwise and can lead to engine damage.
32 Tighten connecting rod bolts (3)   AR03.10-P-6111-02MM
TORQUE SPECIFICATION Connecting rod bolt *BA03.10-P-1001-01E 
33 Turn crankshaft by hand and check for unobstructed movement of crank assembly    
34 Install oil pump MODEL 231 with ENGINE 157, 278 AR18.10-P-6020RKB
MODEL 222 with ENGINE 157, 278 AR18.10-P-6020LFB
MODEL 216 with ENGINE 157, 278
MODEL 221 with ENGINE 157, 278		 AR18.10-P-6020MM
35 Install oil pan MODEL 231 with ENGINE 157, 278 AR01.45-P-7500RKB
MODEL 222 with ENGINE 157, 278 AR01.45-P-7500LFB
MODEL 216, 221 with ENGINE 157, 278 AR01.45-P-7500MMB
36 Install both cylinder heads MODEL 231 with ENGINE 157, 278 Right cylinder head AR01.30-P-5780RKB
Right cylinder head MODEL 222 with ENGINE 157, 278 AR01.30-P-5780LFB
Right cylinder head MODEL 216, 221 with ENGINE 157, 278 AR01.30-P-5780MMB
Left cylinder head MODEL 231 with ENGINE 157, 278 AR01.30-P-5770RKB
Left cylinder head MODEL 222 with ENGINE 157, 278 AR01.30-P-5770LFB
Left cylinder head MODEL 216, 221 with ENGINE 157, 278 AR01.30-P-5770MMB
37 Detach engine from assembly stand    
38 Mount transmission with torque converter ENGINE 157, 278 in MODEL 216, 221, 222, 231  
MODEL 231 with ENGINE 157 with TRANSMISSION 722.93
MODEL 231 with ENGINE 278 with TRANSMISSION 722.9		 AR27.10-P-0500RK
MODEL 222 with ENGINE 278 with TRANSMISSION 722.96 AR27.10-P-0500LHX
MODEL 222 with ENGINE 157 with TRANSMISSION 722.931
MODEL 222 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500LF
MODEL 216, 221 with ENGINE 157 with TRANSMISSION 722.9
with 4MATIC MODEL 216, 221 with ENGINE 278 with TRANSMISSION 722.9 with 4MATIC		 AR27.10-P-0500SYZ
MODEL 216.3, 221.0/1 with ENGINE 157 with TRANSMISSION 722.9
without 4MATIC MODEL 216.3, 221.0/1 with ENGINE 278 with TRANSMISSION 722.9 without 4MATIC		 AR27.10-P-0500SX
39 Install engine with front axle carrier MODEL 222 with ENGINE 157, 278 AR01.10-P-2500LFB
MODEL 231 with ENGINE 157, 278 AR01.10-P-2500RKB
MODEL 216, 221 with ENGINE 157, 278 AR01.10-P-2500MMB
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation ENGINE 157, 278
BE03.10-P-1001-03A Connecting rod bolts Thread Ø M 8X1
Shank length New mm 42, 5
Max. mm 43, 3
CONNECTING ROD

Number Designation ENGINE 157 ENGINE 278
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 25 25
Stage 3 ∠° 90 90
Fig 3: Identifying Tensioning Strap (000 589 04 14 00)
G09974053Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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