Removing Pistons - Cylinders 1-3

Information 

• The specified positions relate to removing and installing components on the engine assembly support with the engine in a vertical position  .
• Mark pistons in installation position using a water-resistant marker  .

1. Unscrew screw plug (M30 x 1.5) -1-  for removing piston pins.
   1. 1.1. Replace sealing ring.
      Fig 1: Identifying Piston Pins Screw Plug

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   To Remove A Piston-Pin Circlip: 

2. Turn the crankshaft and vibration damper to the bottom dead center position -U 1/4 Marking-  and lock at this position using Locating Pin 9595/1 -1-  .
   Fig 2: Identifying Vibration Damper Marking

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   WARNING: Preloaded or pressurized components

   • Risk of eye injuries
   • Risk of bruising

   → Wear personal protective gear.

   → Secure components to prevent them from falling off suddenly.

   Information 

   • Special tool Disassembly Tool 9764 for removing piston-pin circlips must only be turned in a clockwise direction  .
   • Always hold the tool firmly with one hand when using it  .
   • Replace removed piston-pin circlips  .
3. Slide special tool Disassembly Tool 9764  through the assembly bore. The groove -arrow-  for the hook on the circlip must be at 9 O'clock Position  when the engine is positioned vertically.
   Fig 3: Locating Groove For Circlip Hook

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4. Disassembly Tool 9764  must now be pushed into the circlip.
   1. 4.1. Carefully turn the tool to the left and right. You should feel resistance from the hook.
      Fig 4: Positioning Guide Groove Of Tool 9764 In Circlip Hook

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5. Tighten circlip using tool 9764. To do this, turn the hexagonal handle clockwise -arrow-  until you feel a certain amount of resistance.
   Fig 5: Tightening Pre-Tensioning Piston Pin Circlip

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6. Keep the hexagonal handle -1-  tight and turn the pipe -3-  clockwise until you feel a certain amount of resistance. The cheese head bolt -2-  will move horizontally to the left from Position A  in the guide groove.
   Fig 6: Moving Cheese Head Bolt Horizontally

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   1. 6.1. Hold the tool firmly at the pipe and keep it pressed slightly against the piston in a clockwise direction -arrow 2-  . Slowly turn the hexagonal handle -1-  until the cheese head bolt is at Position B  .
      Fig 7: Identifying Tool 9764 Position B

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   2. 6.2. Hold the hexagonal handle -1-  firmly and turn the pipe clockwise -arrow 2-  until you feel a certain amount of resistance. The cheese head bolt will move horizontally to the left from Position B  in the guide groove.
      Fig 8: Identifying Tool 9764 Stop Ahead Position C

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   3. 6.3. Hold the tool firmly at the pipe and press it slightly against the piston. Slowly turn the hexagonal handle using spring force until the cheese head bolt is at Position C  . The circlip engages in the tool with an audible click.
      Fig 9: Identifying Tool 9764 Position C

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   4. 6.4. Slowly pull the tool with the circlip -1-  out of the crankcase -arrow-  . Dispose of old circlip.
      Fig 10: Pulling Tool 9764 Out Of Crankcase

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   To Remove A Piston Pin: 

   Disassembly Tool 9777 

   Fig 11: Identifying Tool 9777 For Removing/Fitting Piston Pins

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   Interchangeable Inserts For Piston Pins:

   1. 53-mm insert for 2.7-liter engine
   2. Roll pin (must be screwed in securely)
   3. 56-mm insert for 3.4-liter and 3.8-liter engine
   Fig 12: Identifying Tool 9777 With Interchangeable Inserts

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7. Disassembly Tool 9777  must be pushed as far as it will go into the piston pin.
   1. 7.1. Hold the tool firmly at the front hexagon -1-  and turn the rear hexagon -2-  anti-clockwise as far as it will go -arrow-  .
      Fig 13: Sliding Tool 9777 Into Piston Pin

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   2. 7.2. Pull out the piston pin -1-  using the correct interchangeable insert -2-  . Inset shows the tensioned piston pin.
      Fig 14: Removing Piston Pin Using Correct Interchangeable Insert

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   3. 7.3. To loosen the piston pin, turn the rear hexagonal handle clockwise until the pin can be removed.

   To Remove A Piston: 

8. Assembly Aid 9783  must be inserted into the cylinder bore from the oil pan side. Then press out the piston (by tapping lightly on the handle with the ball of your hand).
   1. 8.1. Assign the correct piston pin to the piston immediately.
   2. 8.2. Fit Assembly Aid 9795 -1-  (rubber sleeves) on the connecting rod to protect the cylinder liner.
      Fig 15: Identifying Assembly Aid 9795 (Rubber Sleeves) On Connecting Rod

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9. Turn the crankshaft to the bottom dead center position U 2/5 Marking  at the vibration damper and lock at this position using a locating pin (Tool 9595/1) -1-  .
   Fig 16: Identifying Vibration Damper Marking

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   1. 9.1. Repeat steps  3 to  8 for removing piston 2.
10. Turn the crankshaft to the bottom dead center position U 3/6 Marking  at the vibration damper and lock at this position using a locating pin (Tool 9595/1) -1-  .
    Fig 17: Identifying Vibration Damper Marking

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    1. 10.1. Repeat steps  3 to  8 for removing piston 3.
11. Check piston wear during re-installation.

    → 1310IN PISTON WEAR, WEIGHT GROUPS AND IDENTIFICATION MARKINGS .