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

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ENGINES 272, 273 in MODEL 212 

Fig 1: Piston Remove/Install Components (1 Of 2)
G09974059Courtesy of MERCEDES-BENZ USA
Fig 2: Piston Remove/Install Components (2 Of 2)
G09974060Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

22.4.10 Value changed: piston diameter Engine 273.96/97 *BE03.10-P-1001-02D 
REMOVING Removing     
IMPORTANT The ground line on the battery must always  be detached before beginning work on the fuel system otherwise pressure will be lost in the fuel system through opening a vehicle door or the trunk lid Model 212.057/257  
1.1 Remove engine with transmission Vehicles without 4MATIC AR01.10-P-2401EW
1.2 Remove engine with front axle carrier Vehicles with 4MATIC AR01.10-P-2500EW
2 Detach engine from front axle carrier Vehicles with 4MATIC AR01.10-P-2510CWX
3 Detach transmission from engine With transmission 722.9 (except code 722.96) AR27.10-P-0500EV
With transmission 722.96 AR27.10-P-0500CWX
With transmission 711.6 -
With transmission 716.6 -
4 Mount engine onto assembly stand    
5 Detach oil pan Engine 273 with rear sump AR01.45-P-7500EW
Engine 272 with rear sump AR01.45-P-7500EWD
Engine 272, 273 with center sump AR01.45-P-7500EWX
6 Remove oil baffle from cylinder crankcase   AR03.10-P-7021-01SX 
7 Remove cylinder heads Right cylinder head AR01.30-P-5780EW
Left cylinder head AR01.30-P-5770EW
8 Place markings (11) on connecting rod (2) and connecting rod bearing cap (1) at one side IMPORTANT Connecting rod must be installed in the same position and in the same direction.  
9 Remove connecting rod bearing cap (1)    
10 Remove connecting rod (2) with pistons (3) from crankcase in the direction of cylinder head IMPORTANT If pistons are used (3), the arrows indicating the driving direction and the marking of the pistons (3) may no longer be visible because of carbon deposits. For this reason, remove carbon deposits from pistons (3). If arrows indicating the driving direction on pistons (3) are no longer recognizable then these must be newly marked.
The pistons (3) must be installed in the same position and in the same direction.		  
11 Remove circlip (4) for piston pin (5) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
12 Press piston pin (5) out of piston (3)    
INSTALLING Install     
13 Assign piston (3) to cylinder bore   AR03.10-P-7021-02VA 
Test specifications for cylinder bore *BE01.40-P-1001-01I 
Check values for pistons *BE03.10-P-1001-02D 
Check values for pistons *BE03.10-P-1002-02D 
14 Lubricate piston pin (5) and connecting rod small end    
15 Align piston (3) and connecting rod (2) in relation to one another IMPORTANT Install piston (3) with arrow in direction of travel.  
16 Press piston pin (5) by hand into piston (3)    
17 Insert circlip (4) of piston pin (5) into groove on piston (3) IMPORTANT Do not damage piston (3). Place a clean cloth underneath.  
18 Oil cleaned parts (cylinder bores, connecting rod bearing journals, connecting rod bearing shells (10) and piston (3))    
19 Place tensioning strap (6) on piston (3) and tension it IMPORTANT Piston ring end gaps must be offset 120°.  
SPECIAL TOOL Figure
20 Install piston (3) in direction of travel IMPORTANT Pay attention to the arrow (in the direction of travel) on the piston (3).
IMPORTANT Rotate crankshaft so that connecting rod (2) is not touching connecting rod journal when inserting the piston (3) into cylinder bore!		  
21 Check connecting rod bolts (7)   AR03.10-P-6111-01VA 
Test specifications for connecting rod bolts *BE03.10-P-1001-03A 
22 Install connecting rod bearings and connecting rod bearing cap (1) NOTES 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).
IMPORTANT Connecting rods have been cracked during manufacture. The connecting rod bearing caps (1) are not interchangeable and cannot be fitted laterally reversed.		  
Test specifications for crankshaft bearing clearance *BE03.20-P-1002-04E 
23 Tighten connecting rod bolts (7)   AR03.10-P-6111-02VA 
TORQUE SPECIFICATION *BA03.10-P-1001-01E 
24 Turn crankshaft by hand and check for unobstructed movement of crank assembly    
25 Install oil deflector plate   AR03.10-P-7021-01SX 
TORQUE SPECIFICATION *BA18.10-P-1006-01B 
26 Fit oil pan Engine 273 with rear sump AR01.45-P-7500EW
Engine 272 with rear sump AR01.45-P-7500EWD
Engine 272, 273 with center sump AR01.45-P-7500EWX
27 Install cylinder heads Right cylinder head AR01.30-P-5780EW
Left cylinder head AR01.30-P-5770EW
28 Detach engine from engine assembly stand    
29 Attach transmission to engine With transmission 722.9 (except code 722.96) AR27.10-P-0500EV
With transmission 722.96 AR27.10-P-0500CWX
With transmission 711.6 -
With transmission 716.6 -
30 Fit engine on front axle carrier Vehicles with 4MATIC AR01.10-P-2510CWX
31.1 Install engine with front axle carrier Vehicles with 4MATIC AR01.10-P-2500EW
31.2 Install engine with transmission Vehicles without 4MATIC AR01.10-P-2401EW
TEST SPECIFICATIONS FOR CYLINDER BORE

Number Designation Engine 272.91/92/94/95 Engine 272.96/97/98/99
BE01.40-P-1001-01I Cylinder dia. Stage X mm 88.000 to 88.015 92.900 to 92.915
Stage ⓧ mm 88.100 to 88.115 93.000 to 93.015
Repair stage mm 88.250 to 88.265 93.150 to 93.165
TEST SPECIFICATIONS FOR CYLINDER BORE

Number Designation Engine 273.96/97
BE01.40-P-1001-01I Cylinder dia. Stage X mm 98.000 to 98.015
Stage ⓧ mm 98.100 to 98.115
Repair stage mm 98.250 to 98.265
CHECK VALUES FOR PISTONS

Number Designation Engine 272.91/92/94/95 Engine 272.96/97/98/99
BE03.10-P-1001-02D Piston dia. Standard identification X mm 87.973 to 88.003 92.863 to 92.897
Auxiliary stage marking ⓧ mm 88.073 to 88.103 92.963 to 92.997
Repair stage mm 88.223 to 88.253 93.113 to 93.147
BE03.10-P-1002-02D Piston clearance Standard identification X mm 0.003 to 0.042 0.003 to 0.052
Auxiliary stage marking ⓧ mm 0.003 to 0.042 0.003 to 0.052
Repair stage mm 0.003 to 0.042 0.003 to 0.052
CHECK VALUES FOR PISTONS

Number Designation Engine 273.96/97
BE03.10-P-1001-02D Piston dia. Standard identification X mm 97.973 to 98.007
Auxiliary stage marking ⓧ mm 98.073 to 98.107
Repair stage mm 98.223 to 98.257
BE03.10-P-1002-02D Piston clearance Standard identification X mm 0.007 to 0.042
Auxiliary stage marking ⓧ mm 0.007 to 0.042
Repair stage mm 0.007 to 0.042
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation Engine 272 Engine 273
BE03.10-P-1001-03A Connecting rod bolts Thread diameter   M 8X1 8X1
Shank length New mm 39.5 39.5
  max. mm 40.5 40.5
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE

Number Designation Engine 272 Engine 273
BE03.20-P-1002-04E Connecting rod bearing play Radial measurement new mm 0.022...0.066 0.022...0.066
OIL PUMP

Number Designation Engine 272 Engine 273
BA18.10-P-1006-01B Bolt, oil baffle to crankcase Nm 9 9
CONNECTING ROD

Number Designation Engine 272 Engine 273
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5 5
Stage 2 Nm 20 25
Stage 3 ∠° 90 90
Fig 3: Identifying Tensioning Strap (000 589 04 14 00)
G09974061Courtesy of MERCEDES-BENZ USA
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