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

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ENGINES 273 in MODEL 216

ENGINES 272, 273 in MODEL 221

Fig 1: Identifying Piston Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Shown on engine 272

Fig 2: Removing/Installing Piston - Shown On Engine 272

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

23.4.10

Value modified: Piston Ø

Engine 273.96/97

*BE03.10-P-1001-02D

	Removing
1	Remove engine with front axle carrier	Vehicles without 4MATIC	AR01.10-P-2500SX
1	Remove engine with front axle carrier	Vehicles with 4MATIC	AR01.10-P-2500SW
2	Detach engine from front axle carrier	Vehicles without 4MATIC	AR01.10-P-2510SX
2	Detach engine from front axle carrier	Vehicles with 4MATIC	AR01.10-P-2510TW
3	Detach transmission from engine	Vehicles without 4MATIC	AR27.10-P-0500SX
3	Detach transmission from engine	Vehicles with 4MATIC	AR27.10-P-0500SYZ
4	Mount engine onto assembly stand
5	Detach oil pan	Vehicles with engine 272	AR01.45-P-7500SY
		Vehicles with engine 273 without 4MATIC	AR01.45-P-7500SX
		Vehicles with engine 273 and 4MATIC	AR01.45-P-7500SW
6	Remove oil baffle from cylinder crankcase		AR03.10-P-7021-01SX
7	Remove cylinder heads	Right cylinder head	AR01.30-P-5800SY
7	Remove cylinder heads	Left cylinder head	AR01.30-P-5800SX
8	Place markings (11) on connecting rod (2) and connecting rod bearing cap (1) at one side	Connecting rod must be installed in the same position and in the same direction.
9	Remove connecting rod bearing cap (1)
10	Remove connecting rod (2) with pistons (3) from crankcase in the direction of cylinder head	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. The pistons (3) be installed in the same position and in the same direction.
11	Remove circlip (4) for piston pin (5)	Do not damage piston (3). Place a clean cloth underneath.
12	Press the piston pin (5) out of piston (3)
	Install
13	Assign piston (3) to cylinder bore		AR03.10-P-7021-02VA
		Cylinder dia.	*BE01.40-P-1001-01I
		Piston Ø	*BE03.10-P-1001-02D
		Piston clearance	*BE03.10-P-1002-02D
14	Lubricate piston pin (5) and connecting rod small end
15	Align piston (3) and connecting rod (2)	Install piston (3) with arrow in direction of travel.
16	Press piston pin (5) by hand into piston (3)
17	Insert circlip (4) of piston pin (5) into groove on piston (3)	Do not damage piston (3). Place a clean cloth underneath.
18	Oil cleaned parts (cylinder bores, connecting rod bearing journals, connecting rod bearing shells (10) and piston (3))
19	Place tensioning strap (6) on piston (3) and tension it	Piston ring end gaps must be offset 120°.
19	Place tensioning strap (6) on piston (3) and tension it		Figure
20	Install piston (3) in direction of travel	Observe arrow (in direction of travel) on piston (3). Rotate crankshaft so that connecting rod (2) is not touching connecting rod journal when inserting the piston (3) into cylinder bore!
21	Check connecting rod bolts (7)		AR03.10-P-6111-01VA
21	Check connecting rod bolts (7)	Connecting rod bolts	*BE03.10-P-1001-03A
22	Install connecting rod bearings and connecting rod bearing cap (1)	Engine 272	AR03.10-P-6111-06VA
		Connecting rod bearing play	*BE03.20-P-1002-04E
		Engine 273	AR03.10-P-6111-08SX
		Connecting rod bearing play	*BE03.20-P-1002-04E
		Anti-twist locks (8) for connecting rod bearing shells (10) must be located in grooves (9) of connecting rod (2) and connecting rod bearing cap (1). Connecting rods have been cracked during manufacture. The connecting rod bearing caps (1) are not interchangeable and cannot be fitted laterally reversed.	*BA03.10-P-1001-01E
23	Tighten connecting rod bolts (7)		AR03.10-P-6111-02VA
23	Tighten connecting rod bolts (7)		*BA03.10-P-1001-01E
24	Turn crankshaft by hand and check for unobstructed movement of crank assembly
25	Install oil deflector plate		AR03.10-P-7021-01SX
25	Install oil deflector plate		*BA18.10-P-1006-01B
26	Installing oil pan	Vehicles with engine 272	AR01.45-P-7500SY
		Vehicles with engine 273 without 4MATIC	AR01.45-P-7500SX
		Vehicles with engine 273 and 4MATIC	AR01.45-P-7500SW
27	Install cylinder heads	Right cylinder head	AR01.30-P-5800SY
27	Install cylinder heads	Left cylinder head	AR01.30-P-5800SX
28	Detach engine from engine assembly stand
29	Attach transmission to engine	Vehicles without 4MATIC	AR27.10-P-0500SX
29	Attach transmission to engine	Vehicles with 4MATIC	AR27.10-P-0500SYZ
30	Fit engine to front axle carrier	Vehicles without 4MATIC	AR01.10-P-2510SX
30	Fit engine to front axle carrier	Vehicles with 4MATIC	AR01.10-P-2510TW
31	Install engine with front axle carrier	Vehicles without 4MATIC	AR01.10-P-2500SX
31	Install engine with front axle carrier	Vehicles with 4MATIC	AR01.10-P-2500SW

TEST SPECIFICATIONS FOR CYLINDER BORE

Number	Designation			Engine 272.91/92/94/95	Engine 272.96/97/98/99
BE01.40-P-1001-01I	Cylinder dia.	Stage X	mm	88.000...88.015	92.900...92.915
		Stage ⓧ	mm	88.100...88.115	93.000...93.015
		Repair stage	mm	88.250...88.265	93.150...93.165

TEST SPECIFICATIONS FOR CYLINDER BORE

Number	Designation			Engine 273.92	Engine 273.96/97
BE01.40-P-1001-01I	Cylinder dia.	Stage X	mm	92.900...92.915	98.000...98.015
		Stage ⓧ	mm	93.000...93.015	98.100...98.115
		Repair stage	mm	93.150...93.165	98.250...98.265

TEST SPECIFICATIONS FOR PISTONS

Number	Designation			Engine 272.91/92/94/95	Engine 272.96/97/98/99	Engine 273.92
BE03.10-P-1001-02D	Piston Ø	Standard identification X	mm	87.973...88.003	92.863...92.897	92.863...92.897
		Auxiliary stage marking ⓧ	mm	88.073...88.103	92.963...92.997	92.963...92.997
		Repair stage	mm	88.223...88.253	93.113...93.147	93.113...93.147
BE03.10-P-1002-02D	Piston clearance	Standard identification X	mm	0.003...0.042	0.003...0.052	0.003...0.052
		Auxiliary stage marking ⓧ	mm	0.003...0.042	0.003...0.052	0.003...0.052
		Repair stage	mm	0.003...0.042	0.003...0.052	0.003...0.052

TEST SPECIFICATIONS FOR PISTONS

Number	Designation			Engine 273.96/97
BE03.10-P-1001-02D	Piston Ø	Standard identification X	mm	97.973...98.007
		Auxiliary stage marking ⓧ	mm	98.073...98.107
		Repair stage	mm	98.223...98.257
BE03.10-P-1002-02D	Piston clearance	Standard identification X	mm	0.007 to 0.042
		Auxiliary stage marking ⓧ	mm	0.007 to 0.042
		Repair stage	mm	0.007 to 0.042

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number	Designation				Engine 272	Engine 273
BE03.10-P-1001-03A	Connecting rod bolts	Thread dia.		M	8X1	8X1
		Shank length	New	mm	39.5	39.5
			max.	mm	40.5	40.5

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number	Designation			Engine 272	Engine 273
BE03.20-P-1002-04E	Connecting rod bearing play	Radial measurement 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 to crankcase	Nm	9	9

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

Courtesy of MERCEDES-BENZ USA