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

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Engine 264 in model 205, 253

MODIFICATION NOTES

08.05.2019

Method description adapted

Operation steps 1.1, 1.2, 2, 28, 30, 55, 56.1, 56.2

Courtesy of MERCEDES-BENZ USA

Shown on piston crown (5a) with travel direction arrow (D)

Courtesy of MERCEDES-BENZ USA

	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
	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
	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
	Remove
1.1	Remove engine with transmission.	Engine 264 in model 205, 253 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2401MRI
1.2	Remove engine with front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRI
2	Remove engine from front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRI
3	Remove transmission from engine.	Engine 264 in model 205, 253 with transmission 725.0 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR27.10-P-0500MRF
		Engine 264 in model 205, 253 with transmission 725.0 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR27.10-P-0500MRI
4	Attach engine to assembly stand.
	000 588 00 31 00 Assembly stand for cars		WS01.00-Z-3028KOB
5	Remove engine crane and load tilter from engine.
	000 588 00 62 00 Load tilter	Commercially available devices/tools Engine crane	WS01.00-P-0102B
6	Remove cylinder head.		AR01.30-P-5800MRI
7	Remove oil pump.		AR18.10-P-6020MRI
8	Remove balance shaft housing.	Engine 264 in model 253 Engine 264.920 in model 205	AR03.20-P-1105MRI
9	Remove front oil deflector.
	Clean
10	Clean sealing surfaces of crankcase.	Do not use any sharp-edged tools or abrasive paper. Sealing surfaces will otherwise be damaged. Assembly cleaner	*BR00.45-Z-1028-04A
11	Carefully remove combustion residues at top-land zone of cylinder bores and blow out cylinder bores with compressed air.	Do not use any sharp-edged tools or abrasive paper. Otherwise, damage to the cylinder bore will occur. There must not be any combustion residues remaining in the cylinder bores. Non-compliance with result in damage to piston rings (6a, 6b, 6c).
12	Mark connecting rods (2) relative to respective cylinder.	Do not interchange connecting rods (2). Engine damage can occur otherwise.
13	Apply markings (2a) to the connecting rod bearing caps (1) and connecting rods (2).	Connecting rods (2) and connecting rod bearing caps (1) are cracked (broken). Do not interchange. Engine damage can occur otherwise.
14	Remove connecting rod bolts (3).
15	Remove connecting rod bearing caps (1).
16	Mark installation position of the connecting rod bearing shells (4) in the connecting rod bearing caps (1) and connecting rods (2).	Only where connecting rod bearing shells (4) are reused. Do not interchange connecting rod bearing shells (4), connecting rod bearing caps (1) and connecting rods (2). Engine damage can occur otherwise.
17	Check piston crowns (5a) for existing travel direction arrows (D).	If the travel direction arrows (D) on the piston crowns (5a) are no longer recognizable due to soiling or carbonization, ↓ Clean the piston crowns (5a). Do not use any sharp-edged tools or abrasive paper. Otherwise, damage to the piston crowns (5a) will occur. Assembly cleaner If no travel direction arrows (D) are recognizable after cleaning, ↓ Mark piston crowns (5a) with travel direction arrows (D).	*BR00.45-Z-1028-04A
18	Mark pistons (5) relative to respective cylinder.	Only where pistons (5) are reused. Do not interchange pistons (5). Engine damage can occur otherwise.
19	Remove pistons (5) with the corresponding connecting rod (2) upward out of the crankcase.
20	Remove connecting rod bearing shells (4) from the connecting rod bearing caps (1) and corresponding connecting rod (2).
21	Clamp connecting rods (2) with pistons (5) in vise.	Use protective jaws.
22	Mark piston pins (8) and connecting rods (2) relative to pistons (5).	Only where pistons (5) are reused. Do not interchange piston pins (8), connecting rods (2) and pistons (5). Engine damage can occur otherwise.
23	Remove retaining rings (7).	Perform the work on a clean soft base. Piston (5) will otherwise be damaged.
24	Press piston pin (8) out of the pistons (5) and remove pistons (5) from the corresponding connecting rod (2).
25	Remove connecting rods (2) from vise.
26	Clean all crank power unit components.	Do not use any sharp-edged tools or abrasive paper. Otherwise, damage to the crank power unit components will occur. The crank power unit components must be absolutely free of soiling. Engine damage can occur otherwise. Assembly cleaner	*BR00.45-Z-1028-04A
	Check
27	Check pistons (5) and piston rings (6a, 6b, 6c) for wear and damage.	Only where pistons (5) are reused.
	Notes on the assessment of pistons and piston rings	If there are problems, ↓ Replace pistons (5) and/or piston rings (6a, 6b, 6c).	AH03.10-P-0001-04MM
			AR03.10-P-7311MRI
28	Remove piston rings (6a, 6b, 6c) and check for dimensional accuracy.	Only where piston rings (6a, 6b, 6c) are reused. Commercially available devices/tools Outside micrometer	AR03.10-P-7311MRI
		Dimension If there are problems, ↓ Replace piston rings (6a, 6b, 6c) and pistons (5).	*BE03.10-P-1003-05L
29	Check side clearance of piston rings (6a, 6b, 6c).	Only where pistons (5) are reused with already used piston rings (6a, 6b, 6c). Commercially available devices/tools Feeler gauge	AR03.10-P-7311-01MRH
		Piston ring vertical clearance	*BE03.10-P-1001-05L
30	Remove piston rings (6a, 6b, 6c) and check end gap.	Only where piston rings (6a, 6b, 6c) are reused.	AR03.10-P-7311MRI
			AR03.10-P-7311-02MRH
		Commercially available devices/tools Feeler gauge Piston ring end gap	*BE03.10-P-1002-05L
31	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	If there are problems, ↓ Install new connecting rod bearing shells (4) and crankshaft.	AH03.10-P-0001-03MM
			AR03.20-P-4351MRI
32	Check remaining crank power unit components for damage and wear.	If there are problems, ↓ replace corresponding crank power unit components.
33	Check cylinder barrels for wear and damage.
	General information on inspecting cylinder walls	If there are problems, ↓ Replace crankcase.	AH01.00-P-0300-01A
34	Check connecting rod bolts (3) and replace if necessary.		AR03.10-P-6111-01MRH
		Connecting rod bolts	*BE03.10-P-1001-03K
	Install
35	Clamp connecting rods (2) in vise.	Use protective jaws.
36	Wet piston pins (8) and connecting rod small ends with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
37.1	Assign new pistons (5), connecting rods (2) and piston pins (8) to each other.	Only where pistons (5) are replaced.
37.2	Assign previously marked pistons (5), connecting rods (2) and piston pins (8) to each other.	Only where pistons (5) are reused. Note the applied markings during removal. Engine damage can occur otherwise.
38	Manually press piston pins (8) into pistons (5).
39	Install new retaining rings (7).	The openings (5c) of the retaining rings (7) must point vertically in the direction of the piston crowns (5a) after assembly. Engine damage can occur otherwise.
40	Remove connecting rods (2) with pistons (5) from vise.
41	Wet cylinder bores, pistons (5) and connecting rod journals with engine oil.
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
42	Tension piston rings (6a, 6b, 6c) with tensioning strap.	The piston ring end gaps of the piston rings (6a, 6b, 6c) must be offset by 120°. Engine damage can occur otherwise. Tensioning strap	Fig 1
43	Install pistons (5) in direction of travel to respective cylinder.	Turn crankshaft so that the connecting rods (2) do not touch the connecting rod journal when the pistons (5) are installed. Otherwise damage will occur on the connecting rod (2) and crankshaft. Observe the travel direction arrows (D) on the piston crowns (5a). Engine damage can occur otherwise.
44	Assign new connecting rod bearing shells (4).	Only when replacing connecting rod bearing shells (4).	AR03.10-P-6112-01MRH
45.1	Install new connecting rod bearing shells (4).	Only when replacing connecting rod bearing shells (4). Mount connecting rod bearing	AR03.10-P-6111-08MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
45.2	Install previously marked connecting rod bearing shells (4) at respectively marked location.	Only where connecting rod bearing shells (4) are reused. Mount connecting rod bearing	AR03.10-P-6111-08MRH
	Specified engine oils for Cars, Vans (service) - Overview		BB00.40-P-0223-02A
46	Tighten connecting rod bolts (3).		AR03.10-P-6111-02MRH
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
		Bolt, connecting rod bearing cap to connecting rod	*BA03.10-P-1001-01X
47	Crank crankshaft by hand and check for unobstructed movement of crank assembly.	If crankshaft only cranks sluggishly or gets stuck, ↓ Check the assignment and correct seating of the connecting rod bearing shells (4) and the connecting rod bearing caps (1).	AR03.10-P-6112-01MRH
48	Install front oil deflector.	Screw/bolt, oil deflector to crankcase	*BA18.10-P-1005-01W
49	Install balance shaft housing.	Engine 264 in model 253 Engine 264.920 in model 205 Install oil pan only after installation of the oil pump.	AR03.20-P-1105MRI
50	Install oil pump.		AR18.10-P-6020MRI
51	Install cylinder head.		AR01.30-P-5800MRI
52	Attach load tilter to all existing engine lifting lugs and engine crane.
	000 588 00 62 00 Load tilter	Commercially available devices/tools Engine crane	WS01.00-P-0102B
53	Remove engine from assembly stand.
	000 588 00 31 00 Assembly stand for cars		WS01.00-Z-3028KOB
54	Attach transmission to engine.	Engine 264 in model 205, 253 with transmission 725.0 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR27.10-P-0500MRF
		Engine 264 in model 205, 253 with transmission 725.0 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR27.10-P-0500MRI
55	Attach engine to front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)
		Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2510MRI
56.1	Install engine with transmission.	Engine 264 in model 205, 253 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2401MRI
56.2	Install engine with front axle carrier.	Engine 264 in model 205, 253 with code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 264 in model 253 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRP
		Engine 264 in model 205 with code M005 (Vehicles with 4MATIC/all-wheel drive)	AR01.10-P-2500MRI

CHECK VALUES FOR CONNECTING ROD BOLTS

Number	Designation				Engine 264
BE03.10-P-1001-03K	Connecting rod bolts	Thread diameter		M	7 x 1
		Shank length	When new	mm	38
		Shank length	max.	mm	38, 4

CHECK VALUES FOR PISTON RINGS

Number	Designation			Engine 264.915	Engine 264.920
BE03.10-P-1001-05L	Piston ring vertical clearance	Groove 1	mm	0, 04...0, 08	0, 035...0, 075
		Groove 2	mm	0, 03...0, 07	0, 02...0, 06
		Groove 3	mm	0, 01...0, 18	0, 19...0, 31

CHECK VALUES FOR PISTON RINGS

Number	Designation			Engine 264.915	Engine 264.920
BE03.10-P-1002-05L	Piston ring end gap	Groove 1	mm	0, 18...0, 28	0, 2...0, 3
		Groove 2	mm	0, 3...0, 5	0, 3...0, 5
		Groove 3	mm	0, 2...0, 7	0, 2...0, 7

CHECK VALUES FOR PISTON RINGS

Number	Designation			Engine 264.915	Engine 264.920
BE03.10-P-1003-05L	Dimension	Plain compression ring	mm	80, 4x1, 0x2, 75	83, 0x1, 2x3, 1
		Taper-faced hook scraper ring	mm	80, 4x1, 0x2, 70	83, 0x1, 2x2, 9
		Oil scraper ring	mm	80, 4x1, 5x2, 25	83, 0x2, 0x1, 9

CONNECTING ROD

Number	Designation				Engine 264
BA03.10-P-1001-01X	Bolt, connecting rod bearing cap to connecting rod	For initial tightening of new bolts	Stage 1	Nm	5
			Stage 2	Nm	15
			Stage 3	∠°	180
			Stage 4		Loosen bolts
			Stage 5	Nm	5
			Stage 6	Nm	15
			Stage 7	∠°	90
		In case of reusability	Stage 1	Nm	5
			Stage 2	Nm	15
			Stage 3	∠°	90

OIL PUMP

Number	Designation		Engine 264
BA18.10-P-1005-01W	Screw/bolt, oil deflector to crankcase	Nm	9

Fig 1: Identifying Tensioning Strap (000 589 04 14 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01