Remove/install piston - AR03.10-P-7021AMG

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ENGINE 156

MODIFICATION NOTES

1.2.12	Value changed: connecting rod bearing cap on the connecting rod, stage 3	BA03.10-P-1001-01Q
29.2.12	Connecting rod cap to the connecting rod	BA03.10-P-1001-01Q
22.3.12	Connecting rod cap to the connecting rod	BA03.10-P-1001-01Q
14.9.12	Cylinder crankcase lower section Cylinder crankcase upper section	BA03.20-P-1002-01J

Fig 1: Piston Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Piston Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1.1	Remove engine with front axle carrier	ENGINE 156 in MODEL 164, 251	AR01.10-P-2500GZS
1.2	Remove engine	ENGINE 156 in MODEL 204, 209, 211, 212, 216, 219, 221, 230
		MODEL 204 with ENGINE 156	AR01.10-P-2400CMG
		MODEL 212 with ENGINE 156	AR01.10-P-2400EMG
		MODEL 209.377/477 with ENGINE 156.982	AR01.10-P-2400QMG
		MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.10-P-2400TMG
		MODEL 216, 221 with ENGINE 156	AR01.10-P-2400SMG
		MODEL 230.470 with ENGINE 156	AR01.10-P-2400RMG
2	Remove engine from front axle carrier	MODEL 164, 251 with ENGINE 156	AR01.10-P-2510GZS
3	Detach transmission from engine
4	Mount engine onto assembly stand
5	Remove cylinder heads	MODEL 164, 251 with ENGINE 156	AR01.30-P-5800GZS
		MODEL 204, 212 with ENGINE 156	AR01.30-P-5800CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.30-P-5800TMG
		ENGINE 156 in MODEL 216, 221	AR01.30-P-5800SMG
		MODEL 230.470 with ENGINE 156	AR01.30-P-5800RMG
6	Detach oil pan bottom section	MODEL 164, 251 with ENGINE 156	AR01.45-P-7555GZS
		MODEL 204, 212 with ENGINE 156	AR01.45-P-7555CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.45-P-7555TMG
		MODEL 216, 221 with ENGINE 156	AR01.45-P-7555SMG
		MODEL 230.470 with ENGINE 156	AR01.45-P-7555RMG
7	Detach oil pan	MODEL 164, 251 with ENGINE 156	AR01.45-P-7500GZS
		MODEL 204, 212 with ENGINE 156	AR01.45-P-7500CMG
		MODEL 209.377/477 with ENGINE 156.982	AR01.45-P-7500QMG
		MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.45-P-7500TMG
		MODEL 216, 221 with ENGINE 156	AR01.45-P-7500SMG
		MODEL 230.470 with ENGINE 156	AR01.45-P-7500RMG
8	Remove oil pump	MODEL 164, 251 with ENGINE 156	AR18.10-P-6020GZS
		MODEL 204, 212 with ENGINE 156	AR18.10-P-6020CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR18.10-P-6020TMG
		MODEL 216, 221 with ENGINE 156	AR18.10-P-6020SMG
		MODEL 230.470 with ENGINE 156	AR18.10-P-6020RMG
9	Detach engine support
10	Detach refrigerant compressor or compressor from cylinder crankcase and disconnect connector on oil temperature sensor		AR18.40-P-4123AMG
11	Remove vacuum reservoir from cylinder crankcase	On vehicles with vacuum reservoir at the cylinder crankcase
12	Unscrew screw/bolts from cylinder crankcase lower section (Bedplate)
13	Mount crankshaft bracket on the crankshaft	Crankshaft bracket	Fig 4
14	Place markings (11) on connecting rod (2) and connecting rod bearing cap (1) at one side	Connecting rod (2) and connecting rod bearing cap (1) are cracked (broken). They must not be swapped over with each other or installed the wrong way round. The dimensional accuracy will no longer be obtained otherwise.
15	Remove connecting rod bearing cap (1)
16	Remove connecting rod (2) with pistons (3) from cylinder crankcase in the direction of cylinder head	Mark pistons (3) for the cylinder bores. Two variants of piston (3) are used: Piston (3) with travel direction arrow (old) Piston (3) with cast in piston edge (new, without travel direction arrow). View of the piston edge: ↓ See: assign piston (3) to cylinder bore.
			AR03.10-P-7021-03AMG
		For re-installation of used pistons (3), the driving direction arrows and the marking of the pistons (3) may no longer be visible because of carbonization. For this reason, remove carbonization from pistons (3). If arrows indicating the driving direction arrows on the pistons (3) are no longer recognizable then these must be newly marked.
17	Remove retaining ring (4) for piston pin (5)	Do not damage piston (3). Place clean rags underneath as a base.
18	Press piston pin (5) out of piston (3)
	Install
19	Assign piston (3) to cylinder bore	For replacing the connecting rod and the piston (3): ↓ Assign piston (3) to cylinder bore
19	Assign piston (3) to cylinder bore		AR03.10-P-7021-03AMG
20	Lubricate piston pin (5) and connecting rod small end
21	Align piston (3) and connecting rod (2)	Mount piston (3) with arrow in direction of travel (if present).
22	Push piston pins (5) into pistons (3)
23	Insert retaining ring (4) of piston pin (5) in piston (3)	Do not damage piston (3). Place clean rags underneath as a base.
24	Lubricate cleaned parts (cylinder bores, connecting rod journals, connecting rod bearing shells and piston (3))
25	Place tensioning strap (6) on piston (3) and tension it	Piston ring end gaps must be offset 120°.
25	Place tensioning strap (6) on piston (3) and tension it	Tensioning strap	Fig 5
26	Install piston (3) in direction of travel	Observe arrow (in direction of travel) on piston (3) (if present). Turn the crankshaft so that the connecting rod (2) is not at the connecting rod journal when piston (3) is inserted in the cylinder bore!
27	Install connecting rod bearings and connecting rod bearing cap (1)	Anti-twist locks (8) for connecting rod bearing shells (10) must be located in grooves (9) of connecting rod (2) and connecting rod bearing cap (1). Damage can occur otherwise since orderly seating of the connecting rod bearing is no longer present. Connecting rod (2) and connecting rod bearing cap (1) are cracked (broken). They must not be swapped over with each other or installed the wrong way round. The dimensional accuracy will no longer be obtained otherwise!
28	Tighten connecting rod bolts (7)		AR03.10-P-6111-02AMG
		The connecting rod bolts (7) must be replaced. The previously installed connecting rod bolts (7) must not be installed again. Through reuse loosening and associated engine damage can occur. Tighten connecting rod bolts (7) according to tightening specification.
		Connecting rod bearing cap on connecting rod	*BA03.10-P-1001-01Q
29	Turn crankshaft by hand and check for unobstructed movement of crank assembly
30	Remove crankshaft bracket from crankshaft	Crankshaft bracket	Fig 4
	Clean
31	Remove sealant on cylinder crankcase and cylinder crankcase bottom section (Bedplate)		AR01.00-P-0050-01A
		Do not use any sharp-edged tools or abrasive paper. The sealing surfaces can be damaged otherwise.
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
32	Install cylinder crankcase lower section (Bedplate)		AR03.20-P-4351-05AMG
	Information on application of sealant to crankcase bottom section		AH01.40-P-1000-03AMG
		Replace screw/bolts and tighten down according to tightening specification.
		Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	*BA03.20-P-1001-01J
		Cylinder crankcase lower part to cylinder crankcase upper part	*BA03.20-P-1002-01J
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
		Application gun	Fig 3
33	Replace rear crankshaft radial sealing ring	MODEL 164, 251 with ENGINE 156	AR03.20-P-3063GZS
		MODEL 204, 212 with ENGINE 156	AR03.20-P-3063CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR03.20-P-3063TMG
		MODEL 216, 221 with ENGINE 156	AR03.20-P-3063SMG
		MODEL 230.470 with ENGINE 156	AR03.20-P-3063RMG
34	Install vacuum reservoir	On vehicles with vacuum reservoir at the cylinder crankcase
35	Mount engine support	Bolt, engine support to crankcase	*BA22.10-P-1001-02A
36	Mount the refrigerant compressor on the cylinder crankcase		AR18.40-P-4123AMG
37	Install oil pump	MODEL 164, 251 with ENGINE 156	AR18.10-P-6020GZS
		MODEL 204, 212 with ENGINE 156	AR18.10-P-6020CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR18.10-P-6020TMG
		MODEL 216, 221 with ENGINE 156	AR18.10-P-6020SMG
		MODEL 230.470 with ENGINE 156	AR18.10-P-6020RMG
38	Mount oil pan	MODEL 164, 251 with ENGINE 156	AR01.45-P-7500GZS
		MODEL 204, 212 with ENGINE 156	AR01.45-P-7500CMG
		MODEL 209.377/477 with ENGINE 156.982	AR01.45-P-7500QMG
		MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.45-P-7500TMG
		MODEL 216, 221 with ENGINE 156	AR01.45-P-7500SMG
		MODEL 230.470 with ENGINE 156	AR01.45-P-7500RMG
39	Mount oil pan bottom section	MODEL 164, 251 with ENGINE 156	AR01.45-P-7555GZS
		MODEL 204, 212 with ENGINE 156	AR01.45-P-7555CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.45-P-7555TMG
		MODEL 216, 221 with ENGINE 156	AR01.45-P-7555SMG
		MODEL 230.470 with ENGINE 156	AR01.45-P-7555RMG
40	Mount cylinder heads	MODEL 164, 251 with ENGINE 156	AR01.30-P-5800GZS
		MODEL 204, 212 with ENGINE 156	AR01.30-P-5800CMG
		MODEL 209.377/477 with ENGINE 156.982 MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.30-P-5800TMG
		MODEL 216, 221 with ENGINE 156	AR01.30-P-5800SMG
		MODEL 230.470 with ENGINE 156	AR01.30-P-5800RMG
41	Mount transmission to engine
42	Attach engine to front axle carrier	MODEL 164, 251 with ENGINE 156	AR01.10-P-2510GZS
43.1	Install engine with front axle carrier	ENGINE 156 in MODEL 164, 251	AR01.10-P-2500GZS
43.2	Install engine	MODEL 204, 209, 211, 212, 216, 219, 221, 230 with ENGINE 156
		MODEL 204 with ENGINE 156	AR01.10-P-2400CMG
		MODEL 212 with ENGINE 156	AR01.10-P-2400EMG
		MODEL 209.377/477 with ENGINE 156.982	AR01.10-P-2400QMG
		MODEL 211.077/277, 219.377 with ENGINE 156.983	AR01.10-P-2400TMG
		MODEL 216, 221 with ENGINE 156	AR01.10-P-2400SMG
		MODEL 230.470 with ENGINE 156	AR01.10-P-2400RMG
	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
44	Perform an engine test run and check engine for leaktightness		AS00.00-Z-0005-01A

CONNECTING ROD

Number	Designation			ENGINE 156
BA03.10-P-1001-01Q	Connecting rod bearing cap on connecting rod	Stage 1	Nm	10
		Stage 2	Nm	40
		Stage 3	∠°	90

CRANKSHAFT BEARING CAP

Number	Designation				ENGINE 156
BA03.20-P-1001-01J	Bolt for crankshaft bearing cap (lower section of cylinder crankcase/main bearing threaded connection)	M9	Stage 1	Nm	20
			Stage 2	Nm	32
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5		losen
			Stage 6	Nm	20
			Stage 7	Nm	32
			Stage 8	∠°	90
			Stage 9	∠°	90
		M10	Stage 1	Nm	20
			Stage 2	Nm	40
			Stage 3	∠°	90
			Stage 4	∠°	90
			Stage 5		losen
			Stage 6	Nm	20
			Stage 7	Nm	40
			Stage 8	∠°	90
			Stage 9	∠°	90

CRANKSHAFT BEARING CAP

Number	Designation				ENGINE 156
BA03.20-P-1002-01J	Cylinder crankcase lower part to cylinder crankcase upper part	M6	Stage 1	Nm	4
		M6	Stage 2	∠°	90
		M8	Stage 1	Nm	10
		M8	Stage 2	∠°	90

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation			ENGINE 156
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 1	Nm	20
BA22.10-P-1001-02A	Bolt, engine support to crankcase	Stage 2	∠°	90

Fig 3: Identifying Application Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Crankshaft Bracket (156 589 00 40 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Tensioning Strap (000 589 04 14 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite 5970 sealant	A 003 989 98 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10