LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2019 >> A220 Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 53 (Crank Assembly -- 118 Chassis) >> Testing & Repair >> Remove/Install Piston >> Remove/Install Piston - AR03.10-P-7021MFG

Remove/Install Piston - AR03.10-P-7021MFG

WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2023 Mercedes-Benz CLA45 AMG, 2023 Mercedes-Benz CLA35 AMG, 2023 Mercedes-Benz CLA250, 2022 Mercedes-Benz CLA45 AMG, and 2022 Mercedes-Benz CLA35 AMG. However, it is still accessible from the selected car via links, so may be relevant.

Engine 139 in model 118, 177, 247 

G16048182Courtesy of MERCEDES-BENZ USA

Shown on piston crown with travel direction arrow (C) 

G16048183Courtesy of MERCEDES-BENZ USA
WARNING Risk of injury.  Moving parts can pinch, crush or, in extreme cases even sever extremities. No parts of the body or limbs should be within the operating area of mechanical components when moving components. AS00.00-Z-0009-01A
CAUTION Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.		 AS18.00-Z-0001-01A
CAUTION Risk of injury  caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.		 AS00.00-Z-0017-01A
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
REMOVING Remove     
1 Remove transmission.   AR27.10-P-0009MFA
2 Release catalytic converter from exhaust gas turbocharger and remove from engine.   AR49.20-P-0100MFG
3 Attach engine to assembly stand.   AR01.00-P-0002-01MFG
REFER TO SPECIAL TOOLS 000 588 17 31 00 Adapter   WS01.00-P-0202C
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
4 Remove cylinder head.   AR01.30-P-5800MFG
5 Remove oil pan.   AR01.45-P-7500MFG
6 Carefully remove combustion residues at top-land zone of cylinder bores and blow out cylinder bores with compressed air. NOTES There must not be any combustion residues remaining in the cylinder bores.
Otherwise, the piston rings (6a, 6b, 6c) will be damaged.
Assembly cleaner		 *BR00.45-Z-1028-04A 
7 Mark connecting rods (2) relative to respective cylinder. NOTES Do not swap connecting rods (2).
Engine damage can occur otherwise.		  
8 Apply markings (arrow A) to connecting rod bearing caps (1) and connecting rods (2).    
9 Remove connecting rod bolts (3).    
10 Remove connecting rod bearing caps (1).    
11 Mark installation position of connecting rod bearing shells (4) in connecting rod bearing caps (1) and in connecting rods (2). Only where connecting rod bearing shells (4) are reused.
NOTES Do not mix up connecting rod bearing shells (4), connecting rod bearing caps (1), and connecting rods (2).
Engine damage can occur otherwise.		  
12 Mark installation position of pistons (5) relative to respective cylinder. NOTES Do not interchange pistons (5).
Engine damage can occur otherwise.		  
13 Check piston crowns for existing travel direction arrows (C). Only where pistons (5) are reused.
If the travel direction arrows (C) on the piston crowns can no longer be discerned due to contamination and carbonization,
↓
Clean piston crowns.
Assembly cleaner
If no travel direction arrows (C) can be discerned after cleaning,
↓
Mark piston crowns with travel direction arrows (C).		 *BR00.45-Z-1028-04A 
14 Remove pistons (5) with connecting rods (2) upward out of the crankcase.    
15 Remove connecting rod bearing shells (4) from connecting rod bearing caps (1) and connecting rods (2).    
16 Clamp connecting rods (2) with pistons (5) in vise. IMPORTANTCommercially available devices/tools 
Aluminum protective jaws		  
17 Mark piston pins (8) and connecting rods (2) relative to the pistons (5). Only where pistons (5) are reused.
NOTES Do not interchange piston pins (8), connecting rods (2) and pistons (5).
Engine damage can occur otherwise.		  
18 Remove retaining rings (7).    
19 Press piston pins (8) out of pistons (5).    
20 Remove pistons (5) from the connecting rods (2).    
21 Remove connecting rods (2) from vise.    
22 Clean all power unit components. NOTES The power unit components must be absolutely free of soiling.
Engine damage can occur otherwise.
Assembly cleaner		 *BR00.45-Z-1028-04A 
INSPECT Check     
23 Check pistons (5) and piston rings (6a, 6b, 6c) for wear and damage. Where pistons (5) and piston rings (6a, 6b, 6c) are reused.  
  Notes on the assessment of pistons and piston rings   AH03.10-P-0001-04 MM 
    If there are problems:
↓
Replace pistons (5) and piston rings (6a, 6b, 6c).		 AR03.10-P-7311MFG 
24 Check piston rings (6a, 6b, 6c) for dimensional accuracy. When reusing the piston rings (6a, 6b, 6c).
IMPORTANTCommercially available devices/tools 
Outside micrometer
HELD TESTER Dimension		 *BE03.10-P-1003-05L 
    If problems occur:
↓
Install new piston rings (6a, 6b, 6c) and pistons (5).		 AR03.10-P-7311MFG 
25 Check side clearance of the piston rings (6a, 6b, 6c). When reusing the pistons (5) with piston rings (6a, 6b, 6c) that have already been used. AR03.10-P-7311-01MR 
    IMPORTANTCommercially available devices/tools 
Feeler gauge
HELD TESTER Piston ring vertical clearance		 *BE03.10-P-1001-05L 
26 Check end gap of piston rings (6a, 6b, 6c). When reusing the piston rings (6a, 6b, 6c). AR03.10-P-7311-02MR 
    IMPORTANTCommercially available devices/tools 
Feeler gauge
HELD TESTER Piston ring end gap		 *BE03.10-P-1002-05L 
27 Check connecting rod bearing shells (4) and connecting rod journals for wear and damage.    
  Notes on assessing wear on connecting rod bearings and connecting rod journals   AH03.10-P-0001-03 MM 
    If problems occur:
↓
Replace connecting rod bearing shells (4) and/or crankshaft.
Remove/install crankshaft		 AR03.20-P-4351MFG 
    Install and gauge connecting rod bearings AR03.10-P-6111-06MR 
REFER TO CAPACITIES & SPECIFICATIONS   Specified engine oils for Cars, Vans (service) - Overview BB00.40-P-0223-02A
28 Check cylinder barrels.
General information on inspecting cylinder walls		 If problems occur:
↓
Replace crankcase.		 AH01.00-P-0300-01AMG
29 Check connecting rod bolts (3) and replace if necessary.   AR03.10-P-6111-01MFG 
    HELD TESTER Connecting rod bolts *BE03.10-P-1001-03A 
30 Check remaining power unit components for wear and damage. If problems occur:
↓
Replace corresponding power unit components.		  
INSTALLING Install     
31 Clean sealing surfaces of crankcase. Assembly cleaner *BR00.45-Z-1028-04A 
32 Clamp connecting rods (2) in vise. IMPORTANTCommercially available devices/tools 
Aluminum protective jaws		  
33 Wet piston pins (8) and connecting rod small ends with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
34.1 Assign new pistons (5), connecting rods (2) and piston pins (8) to each other. When replacing the pistons (5).  
34.2 Assign previously marked pistons (5), connecting rods (2) and piston pins (8) to each other. When reusing the piston (5).
NOTES Note the applied markings during removal.
Engine damage can occur otherwise.		  
35 Manually press piston pins (8) into pistons (5). NOTES Note the applied markings during removal.
Engine damage can occur otherwise.		  
36 Install retaining rings (7). NOTES The openings (arrow B) of the retaining rings (7) must point vertically in the direction of the piston crowns after assembly.
Engine damage can occur otherwise.
IMPORTANT Replace retaining rings (7).		  
37 Remove connecting rods (2) with pistons (5) from vise.    
38 Wet cylinder bores, pistons (5), and connecting rod journals with engine oil.    
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
39 Attach piston rings (6a, 6b, 6c) to the pistons (5). NOTES Install pistons (5) with piston ring end gaps offset by 120°.
Engine damage can occur otherwise.		  
40 Tension piston rings (6a, 6b, 6c) on pistons (5) using tensioning strap. SPECIAL TOOL Tensioning strap Fig 1
41 Install pistons (5) in the direction of travel to respective cylinder. NOTES
Observe travel direction arrows (C) on the piston crowns.
Engine damage can occur otherwise.
NOTES Turn crankshaft so that, when inserting pistons (5) into the cylinder bores, no connecting rods (2) make contact with the connecting rod journals and oil spray nozzles.
Otherwise, damage will occur to the connecting rods (2), oil spray nozzles, and crankshaft.		  
42 Install connecting rod bearing shells (4).   AR03.10-P-6111-06MR 
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
43 Tighten connecting rod bolts (3).    
Notice  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview   BB00.40-P-0223-02A
      AR03.10-P-6111-02MFG 
    TORQUE SPECIFICATION Connecting rod bolt *BA03.10-P-1001-01E 
    SPECIAL TOOL Tightening angle with magnet Fig 2
44 Crank crankshaft by hand and check for unobstructed movement of crank assembly.   BB00.40-P-0223-02A
REFER TO CAPACITIES & SPECIFICATIONS Specified engine oils for Cars, Vans (service) - Overview If crankshaft only cranks sluggishly or gets stuck,
↓
check assignment and correct seating of the connecting rod bearing shells (4) and connecting rod bearing caps (1) and correct if necessary.		 AR03.10-P-6111-06MR 
45 Install cylinder head.   AR01.30-P-5800MFG
46 Install oil pan.   AR01.45-P-7500MFG
47 Remove engine from assembly stand and position on the lifting platform.   AR01.00-P-0002-01MFG
REFER TO SPECIAL TOOLS 000 588 17 31 00 Adapter   WS01.00-P-0202C
REFER TO SPECIAL TOOLS 000 588 27 31 00 Assembly stand for cars   WS01.00-P-0262B
REFER TO SPECIAL TOOLS 000 588 25 62 00 Lift table IMPORTANT Helper required. WS01.00-P-0264A
48 Attach catalytic converter to the engine.   AR49.20-P-0100MFG
49 Install transmission.   AR27.10-P-0009MFA
CHECK VALUES FOR CONNECTING ROD BOLT

Number Designation Engine 133, 139
BE03.10-P-1001-03A Connecting rod bolts Thread diameter   M 8x1
Shank length When new mm 42, 5
max. mm 43, 3
CHECK VALUES FOR PISTON RINGS

Number Designation Engine 139
BE03.10-P-1001-05L Piston ring vertical clearance Groove 1 mm 0, 02...0, 065
Groove 2 mm 0, 02...0, 06
Groove 3 mm 0, 03...0, 2
CHECK VALUES FOR PISTON RINGS

Number Designation Engine 139
BE03.10-P-1002-05L Piston ring end gap Groove 1 mm 0, 18...0, 28
Groove 2 mm 0, 3...0, 5
Groove 3 mm 0, 2...0, 7
CHECK VALUES FOR PISTON RINGS

Number Designation Engine 139
BE03.10-P-1003-05L Dimension Plain compression ring mm 83, 0x1, 2x2, 75
Taper-faced hook scraper ring mm 83, 0x1, 0x2, 7
Oil scraper ring mm 83, 0x2, 0x2, 25
CONNECTING ROD

Number Designation Engine 139
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 30
Stage 3 ∠° 90
Fig 1: Identifying Tensioning Strap (000 589 04 14 00)
G12083117Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Tightening Angle With Magnet (450 589 00 13 00)
G16054152Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
scientia non olet · About LEMON Manuals