Removing Pistons - Cylinders 1-3

Information 

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

1. Mark pistons 1-3 in installation position using a touch-up stick. > Marking pistons 

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   Marking pistons

2. Unscrew screw plug -1-  using a Torx socket-wrench insert T80.

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   Screw plug for removing/fitting piston pins

   To remove piston-pin circlips: 

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

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   Disconnecting vibration damper

   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 

   • 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. 
4. > 9764 - Disassembly tool  with groove -arrow-  at approx. 9 o'clock  position must be pushed through the assembly bore.

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   Groove for circlip hook (at approx. 9 o'clock position) when crankcase is positioned vertically

5. > 9764 - Disassembly tool  must be pushed in on the circlip. Then carefully turn it to the left and right until you feel a certain amount of resistance on the hook > Positioning guide groove of tool 9764 in hook on circlip. 

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   Positioning guide groove of tool 9764 in hook on circlip

6. > 9764 - Disassembly tool  must now be turned -arrow-  until you feel a certain amount of resistance.

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   Pre-tensioning piston pin circlip

7. > 9764 - Disassembly tool-1-  must be held securely while turning the pipe -3-  clockwise until you feel a certain amount of resistance.

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   Tool 9764 at position A

8. Hold the pipe firmly and keep it pressed slightly against the piston in a clockwise direction -arrow 2-  . > 9764 - Disassembly tool-1-  must now be pulled slowly until the screw is at position -B-  .

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   Tool 9764 at position B

9. > 9764 - Disassembly tool-1-  must be held securely while turning the pipe clockwise -2-  until you feel a certain amount of resistance.

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   Tool 9764 at stop ahead of position C

   Information 

   • The circlip will engage in the tool with an audible click. 
10. Hold the pipe firmly and press it slightly against the piston. > 9764 - Disassembly tool-1 -  must now be pulled slowly with spring force until the screw is at position -C-  .

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    Tool 9764 at position C

11. > 9764 - Disassembly tool  with circlip -1-  must now be pulled slowly out of the crankcase -arrow-  . Dispose of the circlip.

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    Pulling disassembly tool out of crankcase

    > 9777 - Disassembly tool for piston pins 

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    Disassembly tool for removing/fitting piston pins

    Interchangeable inserts for piston pins: 

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    Disassembly tool 9777 with interchangeable insert

    1	56 mm insert for 3.0-litre engine
    2	Roll pin (screw in tightly]

12. > 9777 - Disassembly tool  must be pushed as far as it will go into the piston pin.

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

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    Securing piston pin on tool 9777

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

    Inset shows the tensioned piston pin. 

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    Pulling out piston pin

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

13. > 9783 - Assembly aid  must be pushed into the cylinder bore from the oil pan side. Then press out the piston by tapping lightly on the grip handle with the ball of your hand.

    Assign the correct piston pin to the piston immediately.

    > 9795 - Assembly aid  (rubber sleeves) -1-  must be fitted on the connecting rod.

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    Assembly aid 9795 for connecting rods

14. Turn the crankshaft at the vibration damper to position -F-  bottom dead center -UT2/5-  and fix at this position using > 9595/1 - locating pin-1-  .

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    Disconnecting vibration damper

15. Repeat steps See  to See  for removing piston 2.
16. Turn the crankshaft at the vibration damper to position -B-  bottom dead center -UT 3/6-  and fix at this position using > 9595/1 - locating pin-1-  .

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    Disconnecting vibration damper

17. Repeat steps See  to See  for removing piston 3.
18. Check piston wear during re-installation.