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

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ENGINE 152 in MODEL 172 

ENGINE 157 in MODEL 212, 218 

ENGINE 278 in MODEL 207, 212, 218 

Fig 1: Piston Remove/Install Components
G09974055Courtesy of MERCEDES-BENZ USA

Piston with travel direction arrow 

Fig 2: Piston Remove/Install Components - Piston With Travel Direction Arrow
G09974056Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1 Remove engine with front axle carrier MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.10-P-2500ELB
MODEL 172.4 with ENGINE 152.9 AR01.10-P-2500MMI
2 Detach transmission with torque converter ENGINE 152 in MODEL 172
ENGINE 157 in MODEL 212, 218
ENGINE 278 in MODEL 207, 212, 218		  
MODEL 207 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96) AR27.10-P-0500CV
MODEL 212 with ENGINE 278 with TRANSMISSION 722.96
MODEL 218 with ENGINE 278 with TRANSMISSION 722.96		 AR27.10-P-0500CWX
MODEL 172 with ENGINE 152 with TRANSMISSION 722.9 AR27.10-P-0500W
MODEL 212 with ENGINE 157 with TRANSMISSION 722.931/971
MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722 (except 722.96)
MODEL 218 with ENGINE 157 with TRANSMISSION 722.931		 AR27.10-P-0500EV
3 Secure engine to assembly stand Passenger car engine assembly stand  
4 Remove both cylinder heads MODEL 172.4 with ENGINE 152.9
Left cylinder head		 AR01.30-P-5770MMI
Left cylinder head MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.30-P-5770ELB
Right cylinder head MODEL 172.4 with ENGINE 152.9 AR01.30-P-5780MMI
Right cylinder head MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.30-P-5780ELB
5 Remove oil pan MODEL 172.4 with ENGINE 152.9 AR01.45-P-7500MMI
MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.45-P-7500ELB
6 Remove oil pump MODEL 172.4 with ENGINE 152.9 AR18.10-P-6020MMI
MODEL 207 with ENGINE 278 AR18.10-P-6020FH
MODEL 212, 218 with ENGINE 157, 278 AR18.10-P-6020EL
7 Mark installation position on the connecting rod bearing cap (1) and connecting rod (2) IMPORTANT The connecting rods (2) must be mounted on the same cylinder and in the same direction (arrow A).  
8 Remove connecting rod bolts (3)    
9 Remove connecting rod bearing cap (1)    
10 Remove connecting rod bearing shells (4) and mark if necessary relative to the associated connecting rod (2) and connecting rod bearing cap (1) IMPORTANT The connecting rod bearing shells (4) must be mounted on the same cylinder and in the same direction.  
11 Mark installation position and also direction of travel on piston (5) if necessary IMPORTANT The pistons (5) must be mounted on the same cylinder and in the same direction.
If the travel direction arrows (picture) on piston (5) are no longer recognizable due to soiling or carbonization:
↓
The pistons (5) must be cleaned.
If no travel direction arrows can be recognized after cleaning:
↓
The pistons must marked ourself with travel direction arrows (arrow D).		  
12 Remove piston (5) with connecting rod (2) upwards out of the crankcase    
13 Check piston rings (6a, 6b, 6c) for damage    
14 Remove piston rings (6a, 6b, 6c) When replacing the piston rings (6a, 6b, 6c)  
  AR03.10-P-7311EL 
15 Remove retaining ring (7) for piston pin (8)    
16 Mark piston pin (8) and connecting rod (2) relative to the piston (5) IMPORTANT The piston pin (8) and connecting rod (2) must be mounted on the same piston (5) and in the same direction.  
17 Press piston pin (8) out of piston (5)    
CLEAN Clean     
18 Clean all power unit components NOTES The power unit components must be absolutely free of soiling.
Engine damage may occur otherwise.		  
Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
19 Check all power unit components for damage    
20 Check cylinder barrel    
IMPORTANT General information on inspecting cylinder walls AH01.00-P-0300-01VA
IMPORTANT General information on inspecting cylinder walls AH01.00-P-0300-01MM
INSTALLING Install     
21 Assign piston (5) to the respective cylinder bore When replacing the pistons (5).  
ENGINE 157 in MODEL 212, 218
ENGINE 278 in MODEL 207, 212, 218		 AR03.10-P-7021-03MM 
22 Lubricate piston pin (8) and connecting rod small end    
23 Align piston (5) and connecting rod (2) relative each other IMPORTANT Note markings to restore the correct installation position.  
24 Press piston pin (8) by hand into piston (5)    
25 Insert retaining ring (7) of piston pin (8) into groove on piston (5) IMPORTANT The opening of the retaining ring (7) must point vertically in the direction of the piston crown (5a) (arrows B and C) after assembly.  
26 Mount piston rings (6a, 6b, 6c) For replacement of the piston rings (6a, 6b, 6c) or the piston (5)  
  AR03.10-P-7311EL 
SPECIAL TOOL Pliers Fig 4
27 Lubricate cylinder bore, piston (5), connecting rod bearing shell (4) and connecting rod journal    
28 Tension piston rings (6a, 6b, 6c) onto the piston (5) using the tensioning strap IMPORTANT The pistons (5) must be installed with piston ring end gaps installed offset by 120 0 degrees.  
SPECIAL TOOL Tensioning strap Figure
29 Install piston (5) in direction of travel IMPORTANT Note travel direction arrow or marking on piston (5).
IMPORTANT Turn crankshaft until insertion of the piston (5) in the cylinder bore until no connecting rod (2) touches the connecting rod journal.		  
30 Check connecting rod bolts (3)   AR03.10-P-6111-01MM 
Connecting rod bolts *BE03.10-P-1001-03A 
31 Install connecting rod bearing shells (4) and put on connecting rod bearing cap (1)   AR03.10-P-6111-06MM 
NOTES One must ensure that the anti-twist lock (b) for the connecting rod bearing shell (4) lies on the respective inner edge of the groove (a). The connecting rod bearing shells (4) will not sit in the middle otherwise and can lead to engine damage.  
32 Tighten connecting rod bolts (3)   AR03.10-P-6111-02MM 
TORQUE SPECIFICATION
ENGINE 157 in MODEL 212, 218
ENGINE 278 in MODEL 207, 212, 218		 *BA03.10-P-1001-01E 
TORQUE SPECIFICATION
ENGINE 152 in MODEL 172		 *BA03.10-P-1001-01T 
33 Turn crankshaft by hand and check for unobstructed movement of crank assembly    
34 Install oil pump MODEL 212, 218 with ENGINE 157, 278 AR18.10-P-6020EL
MODEL 207 with ENGINE 278 AR18.10-P-6020FH
MODEL 172.4 with ENGINE 152.9 AR18.10-P-6020MMI
35 Install oil pan MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.45-P-7500ELB
MODEL 172.4 with ENGINE 152.9 AR01.45-P-7500MMI
36 Install both cylinder heads MODEL 172.4 with ENGINE 152.9
Left cylinder head		 AR01.30-P-5770MMI
Left cylinder head MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.30-P-5770ELB
Right cylinder head MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.30-P-5780ELB
Right cylinder head MODEL 172.4 with ENGINE 152.9 AR01.30-P-5780MMI
37 Detach engine from assembly stand    
38 Attach transmission with torque converter ENGINE 152 in MODEL 172
ENGINE 157 in MODEL 212, 218
ENGINE 278 in MODEL 207, 212, 218		  
MODEL 207 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96) AR27.10-P-0500CV
MODEL 212 with ENGINE 157 with TRANSMISSION 722.931/971
MODEL 212, 218 with ENGINE 278 with TRANSMISSION 722.9 (except 722.96)
MODEL 218 with ENGINE 157 with TRANSMISSION 722.931		 AR27.10-P-0500EV
MODEL 172 with ENGINE 152 with TRANSMISSION 722.9 AR27.10-P-0500W
MODEL 212 with ENGINE 278 with TRANSMISSION 722.96
MODEL 218 with ENGINE 278 with TRANSMISSION 722.96		 AR27.10-P-0500CWX
39 Install engine with front axle carrier MODEL 207 with ENGINE 278
MODEL 212, 218 with ENGINE 157, 278		 AR01.10-P-2500ELB
MODEL 172.4 with ENGINE 152.9 AR01.10-P-2500MMI
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation ENGINE 152 ENGINE 157, 278
BE03.10-P-1001-03A Connecting rod bolts Thread Ø   M 8X1 8X1
Shank length New mm 42, 5 42, 5
Max. mm 43, 3 43, 3
CONNECTING ROD

Number Designation ENGINE 157 ENGINE 278
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 25 25
Stage 3 ∠° 90 90
CONNECTING ROD

Number Designation Engine 152
BA03.10-P-1001-01T Connecting rod bolt Stage 1 Nm 40
Stage 2 ∠° 90
Fig 3: Identifying Tensioning Strap (000 589 04 14 00)
G09974057Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Pliers (000 589 51 37 00)
G09974058Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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