Removing Pistons - Cylinders 1-3

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

The specified positions are for removing and installing components on the engine assembly support with the engine in a vertical position.

Information

Turn special tool > 9764 - disassembly tool only clockwise for removing the piston-pin circlips.
Always hold the tool firmly with one hand when using it.
Replace removed piston-pin circlips.

Information

The circlip will engage in the tool with an audible click.

Mark installation position of the pistons -1 to 3- with a touch-up stick.

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Pistons 1 to 3
Unscrew screw plug -1- .

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Screw plug
Turn the crankshaft and vibration damper to position -D- bottom dead center -UT 1/4- and lock at this position using > 9595/1 - locating pin-1- .

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Vibration damper
Push > 9764 - disassembly tool with groove -Arrow- at about 9 o'clock position through the assembly bore.

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Groove position for circlip hook
Position > 9764 - disassembly tool on the circlip -1- and carefully turn it to the left and right until you feel a certain amount of resistance on the hook.

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Circlip
Hold > 9764 - disassembly tool-1- securely while turning the pipe -3- clockwise until you feel a certain amount of resistance.

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Tool 9764 at position A
Hold the pipe firmly and keep it pressed slightly against the piston in a clockwise direction -arrow 2- . Pull > 9764 - disassembly tool-1- slowly until the screw is at position -RHD vehicle - .

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Tool 9764 at position B
Hold > 9764 - disassembly tool-1- securely while turning the pipe -2- clockwise until you feel a certain amount of resistance.

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Tool 9764 at stop ahead of position C
Hold the pipe firmly and press it slightly against the piston. Now pull > 9764 - disassembly tool-1- slowly with spring force until the screw is at position -Item C- .

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Tool 9764 at position C
Slowly pull > 9764 - disassembly tool with circlip -1- out of the crankcase -Arrow- and dispose of the circlip.

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Disassembly tool

Push > 9777 - disassembly tool as far as it will go into the piston pin.

11.1 Hold the middle knob -1- securely and turn knob -2- anti-clockwise as far as it will go -Arrow- .

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Piston pin on tool 9777

11.2 Pull out piston pin -1- using interchangeable insert -2- .

Inset shows the tensioned piston pin.

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Piston pin

11.3 Turn the rear knob clockwise until the piston pin can be removed.

Push > 9783 - assembly aid into the cylinder bore from the oil pan side and press out the piston by tapping lightly on the grip of the > 9783 - assembly aid with the ball of your hand.

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Assembly aid 9795 for connecting rods
1. 12.1 Match the pistons to the correct piston pin immediately after removal and place them where they will not get mixed up.
2. 12.2 Fit > 9795 - assembly aid-1- onto the connecting rod.
Turn the crankshaft on the vibration damper to position -F- bottom dead center -UT 2/5- and lock at this position using > 9595/1 - locating pin-1- .

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Vibration damper
Repeat steps See to See for removing piston 2.
Turn the crankshaft on the vibration damper to position -RHD vehicle - bottom dead center -UT 3/6- and lock at this position using > 9595/1 - locating pin-1- .

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Vibration damper
Repeat steps See to See for removing piston 3.
If pistons have to be re-installed:
Check pistons for wear.