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

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ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221 

Fig 1: Piston Remove/Install Components
G09974050Courtesy of MERCEDES-BENZ USA

Shown on engine 651.911 

Fig 2: Piston Remove/Install Components - Shown On Engine 651.911
G09974051Courtesy of MERCEDES-BENZ USA

Shown on engine 651.912 

Fig 3: Piston Remove/Install Components - Shown On Engine 651.912
G09974052Courtesy of MERCEDES-BENZ USA
REMOVING Removing     
1 Disconnect ground line for on-board electrical system battery (G1) NOTES Insulate ground line. Unwanted contact of the disconnected ground line with the ground point of the on-board electrical system battery can occur otherwise.  
Model 166 AR54.10-P-0003GZ
Model 172 AR54.10-P-0003W
Model 204 AR54.10-P-0003CW
Model 207, 212, 218 AR54.10-P-0003EW
Model 221.0/1 AR54.10-P-0003SX
2 Secure vehicle on vehicle lift Model 166 AR00.60-P-0100GZ
Model 172 AR00.60-P-0100T
Model 204, 207 AR00.60-P-0100CW
Model 212, 218 AR00.60-P-0100EWS
Model 221.0/1 AR00.60-P-0100SX
3.1 Remove underfloor paneling MODEL 166.0 AR61.30-P-1001GQ
3.2 Remove bottom sections of soundproofing Model 172.4 AR94.30-P-5300W
Model except 204.9, 204, 207, 212, 218 AR94.30-P-5300EW
3.3 Detach lower engine compartment paneling Model 204.9 AR61.20-P-1105CY
Model 221 except CODE (Z07) Top protection AR61.20-P-1105SX
4.1 Remove engine Model 172, 204 except 4MATIC AR01.10-P-2400CDA
Model 207, 212, 218 except 4MATIC AR01.10-P-2400OMA
Model 221 AR01.10-P-2400SXA
4.2 Remove engine with front axle carrier MODEL 166.0 AR01.10-P-2500GQA
    Model 204 only 4MATIC AR01.10-P-2500OMD
5 Detach engine from front axle carrier Model 166, 204.9, 212, 218 AR01.10-P-2510OMD
6 Secure engine to assembly stand Passenger car engine assembly stand  
7 Remove flywheel or driven plate IMPORTANT Check pilot bearing in flywheel or clutch plate. In the case of noisy or rough running or wear, the flywheel () or clutch plate should be replaced. AR03.30-P-8001CD
8 Remove cylinder head   AR01.30-P-5800CD
9 Clean piston crown and sealing surfaces on cylinder crankcase NOTES Do not use any sharp-edged tools or abrasive paper. The piston crown or the sealing surfaces on the cylinder crankcase can be damaged otherwise.  
10 Carefully remove combustion residues in cylinder bore fire land zone and blow out cylinder bore with compressed air. NOTES There must not be any combustion residues remaining in the cylinder bore. The piston rings may bet damaged otherwise.
IMPORTANT Cover piston crown, if necessary position piston (4) on bottom dead center		  
11 Mark installation position of piston (4) in relation to corresponding cylinder IMPORTANT When engine is running, the stamped direction arrows or color dots can be no longer visible.
If necessary, mark piston (4) with color. Mark on side opposite force output.		  
12.1 Remove oil pan bottom section Model 172.204 (except 204.9), 212 except 4MATIC
Model 207, 218
Model 204 (except 204.9), 212 with 4MATIC		 AR01.45-P-7555CD
Model 221 AR01.45-P-7555SYZ
12.2 Remove oil pan MODEL 166.0 AR01.45-P-7500GQA
Model 204, 212 with 4MATIC AR01.45-P-7500OMD
Model 204.9 except 4MATIC AR01.45-P-7500OND
13 Remove oil suction pipe (8) bolts (7) and the oil spray protection (8a)    
14 Detach oil suction pipe (8) and Oil spray protection (8a) downwards    
15 Mark connecting rod (2) and connecting rod bearing cap (1) relative to each other on inlet side (arrow B). IMPORTANT While rotating the crankshaft ensure that connecting rods (2) do not get jammed. Do not interchange connecting rod bearing shells.  
16 Unscrew connecting rod bolts (3), remove connecting rod bearing cap (1) from connecting rod (2) and remove lower connecting rod bearing shell IMPORTANT If necessary, remove lower connecting rod bearing shell from crankshaft and assign to connecting rod bearing cap (1).  
17 Remove piston (4) with connecting rod (2) upward from cylinder crankcase and remove upper connecting rod bearing shell IMPORTANT Assign upper connecting rod bearing shell to connecting rod (2).  
18 Mark piston (4) and connecting rod (2) in relation to one another IMPORTANT Mark piston (4) and connecting rod (2) with paint only.  
19 Clamp connecting rod (2) into vise IMPORTANT Use protective jaws.  
20 Remove circlip (5)    
21 Press piston pin (6) out of piston (4) and remove piston (4) from connecting rod (2)    
22 Remove connecting rod (2) from vise    
CLEAN Clean     
23 Clean cylinder bores, connecting rod journal on crankshaft, piston (4), upper and lower connecting rod bearing shells, connecting rods (2) and connecting rod bearing cap (1)    
INSPECT Checking     
24 Check piston (4) and piston pins (6) for wear and damage. IMPORTANT If applicable, replace piston (4) and piston pins (6).  
25 Check piston rings on piston (4) for damage and chipping on coating. IMPORTANT Replace piston rings if necessary.
See: ↓		  
Remove/install piston rings AR03.10-P-7311T 
26 Check connecting rod bearing cap (1) and connecting rod (2) for discoloration and damage IMPORTANT Replace connecting rod (1) and connecting rod bearing cap (2) if necessary.
If discolored, additionally check crankshaft for wear, damage and dimensional accuracy.
See: ↓		  
Measure crankshaft and remount in bearings AR03.20-P-4355CD
MEASURING Measure     
27 Measure cylinder bores IMPORTANT Only if honing pattern in the cylinder bores is visible or undamaged.
IMPORTANT If cylinder bore is not abnormally worn and cylinder shape or roundness is within tolerance, new pistons (4) can be installed in the used engine.		 AR01.40-P-9202T
INSTALLING Install     
28 Clamp connecting rod (2) into vise IMPORTANT Use protective jaws.  
29 Lubricate piston pin (6) and connecting rod bores in piston (4)    
30 Assemble piston (4) and connecting rod (2) IMPORTANT Assemble piston (4) and connecting rod (2) according to provided markings (arrow).  
31 Insert piston pins (6) by hand into piston (4) and connecting rod (2)    
32 Insert retaining ring (5) into the groove on the piston (4) NOTES Carefully insert retaining ring (5). Damage can occur on the piston (4) otherwise.  
33 Remove connecting rod (2) from vise    
34 Lubricate cylinder bores, connecting rod journal on crankshaft, piston (4), upper and lower connecting rod bearing shells, connecting rods (2) and connecting rod bearing cap (1)    
35 Insert upper connecting rod bearing shell into connecting rod (2) NOTES Insert the upper connecting rod bearing shell untilted into the connecting rod (2). Damage can occur to the connecting rod otherwise.
IMPORTANT Observe assignment for upper connecting rod bearing shell in relation to connecting rod (2).		  
36 Place tensioning strap for piston rings on piston (4) and tension IMPORTANT The piston ring gaps should be offset 120°.  
SPECIAL TOOL Tensioning strap Figure
37 Insert piston (4) with connecting rod (2) into corresponding cylinder bore IMPORTANT Embossed direction arrows or colored dots or markings on piston (4) must point in the direction opposite to the force specified.  
38 Press piston (4) into cylinder bore. IMPORTANT Press piston (4) into cylinder bore only until the SPECIAL TOOL tensioning strap can be removed. The connecting rod (2) should not be positioned on the crankshaft, if necessary turn crankshaft. The SPECIAL TOOL tensioning strap must be placed on the cylinder crankcase when pressing in the piston (4), if necessary reposition SPECIAL TOOL tensioning strap.  
SPECIAL TOOL Tensioning strap Figure
39 Check connecting rod bolts (3) IMPORTANT If too long or damaged, replace connecting rod bolts (3). AR03.10-P-6111-01T 
  *BE03.10-P-1001-03I 
40 Insert lower connecting rod bearing shell into connecting rod bearing cap (1) NOTES Insert lower connecting rod bearing shell untitled in connecting rod bearing cap (1). Damage can occur to the connecting rod otherwise.
IMPORTANT Observe assignment for lower connecting rod bearing shell in relation to connecting rod bearing cap (1).		  
41 Position connecting rod bearing cap (1) at crankshaft and connecting rod (2) and tighten connecting rod bolts (3) NOTES The connecting rod (2) and connecting rod bearing cap (1) are cracked (broken) and must not be swapped with others or installed the wrong way round. The dimensional accuracy will no longer be present and engine damage may occur otherwise.
IMPORTANT Assemble connecting rod bearing cap (1) and connecting rod (2) according to markings (arrow B).		 AR03.10-P-6111-02T 
TORQUE SPECIFICATION *BA03.10-P-1001-01R 
SPECIAL TOOL External Torx set Figure
42 Spin crankshaft and check for unobstructed movement IMPORTANT If crankshaft is hard to turn, determine cause and corresponding repair measure.  
43 Install oil suction pipe (8) and oil spray protection (8a) IMPORTANT Replace O-ring (9) for oil suction pipe (8). First insert oil suction pipe (8) fully into oil pan (10) and then tighten.  
44 Screw in oil suction pipe (8) bolts (7) and the oil spray protection (8a) SPECIAL TOOL *BA18.10-P-1002-01O 
45.1 Install oil pan bottom section Model 172, 204 (except 204.9), 212 except 4MATIC
Model 207, 218
Model 204 (except 204.9), 212 with 4MATIC		 AR01.45-P-7555CD
Model 221 AR01.45-P-7555SYZ
45.2 Install oil pan MODEL 166.0 AR01.45-P-7500GQA
Model 204, 212 with 4MATIC AR01.45-P-7500OMD
Model 204.9 except 4MATIC AR01.45-P-7500OND
46 Install cylinder head   AR01.30-P-5800CD
47 Install flywheel/drive plate   AR03.30-P-8001CD
48 Attach engine to front axle carrier Model 166, 204.9, 212 AR01.10-P-2510OMD
49.1 Install engine Model 172, 204 except 4MATIC AR01.10-P-2400CDA
Model 207, 212, 218 except 4MATIC AR01.10-P-2400OMA
Model 221 AR01.10-P-2400SXA
49.2 Remove engine with front axle carrier MODEL 166.0 AR01.10-P-2500GQA
Model 204 only 4MATIC AR01.10-P-2500OMD
50.1 Install bottom section of soundproofing Model 172.4 AR94.30-P-5300W
Model except 204.9, 204, 207, 212, 218 AR94.30-P-5300EW
50.2 Install lower engine compartment paneling. Model 204.9 AR61.20-P-1105CY
Model 221 except CODE (Z07) Top protection AR61.20-P-1105SX
51 Release vehicle on lifting platform Model 166 AR00.60-P-0100GZ
Model 172 AR00.60-P-0100T
Model 204, 207 AR00.60-P-0100CW
Model 212, 218 AR00.60-P-0100EWS
Model 221.0/1 AR00.60-P-0100SX
52 Connect ground line to on-board electrical system battery Model 166 AR54.10-P-0003GZ
Model 172 AR54.10-P-0003W
Model 204 AR54.10-P-0003CW
Model 207, 212, 218 AR54.10-P-0003EW
Model 221.0/1 AR54.10-P-0003SX
53 Connect STAR DIAGNOSIS, read out fault memory and erase if required IMPORTANT Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work. AD00.00-P-2000-04A
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
54 Check for leaks with engine running
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation Engine 651
BE03.10-P-1001-03I Connecting rod bolt Thread diameter   M 8X1
Shank length New mm 47 (± 0.3)
  max. mm 48
CONNECTING ROD

Number Designation Engine 651
BA03.10-P-1001-01R Screw/bolt, connecting rod bearing cap to connecting rod At initial tightening torque after cracking Stage 1 Nm 5
Stage 2 Nm 25
Stage 3 ∠° 180
For subsequent tightening Stage 1 Nm 5
Stage 2 Nm 25
Stage 3 ∠° 90
OIL PUMP

Number Designation Engine 651
BA18.10-P-1002-01O Screw/bolt, oil suction pipe to bearing housing M6 Stage 1 Nm 6
Stage 2 ∠° 90
M8 - Nm 34
Fig 4: Identifying Tensioning Strap (000 589 04 14 00)
G09974053Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying External Torx Set (001 589 76 09 00)
G09974054Courtesy of MERCEDES-BENZ USA
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