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

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ENGINE 276 in MODEL 172, 204, 207, 212, 218 

Fig 1: Piston Remove/Install Components
G09974062Courtesy of MERCEDES-BENZ USA

Piston with travel direction arrow 

Fig 2: Piston Remove/Install Components - Piston With Travel Direction Arrow
G09974063Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
1.1 Remove engine with front axle carrier Engine 276 in model 204, 207, 212 with code M005 (4MATIC)  
ENGINE 276.8 in MODEL 212.067/099/167/168/267/299 AR01.10-P-2500ELS
MODEL 212.08/28 with ENGINE 276.9 AR01.10-P-2500ELB
MODEL 204.08/98, 207.38 with ENGINE 276.9 AR01.10-P-2500FH
1.2 Remove engine with transmission Engine 276 in model 172, 204, 207, 212, 218 except code M005 (4MATIC)  
ENGINE 276.8 in MODEL 207 AR01.10-P-2401FT
ENGINE 276.8 in MODEL 212.061/065/165/261/265 AR01.10-P-2401ELS
MODEL 212.095/195 with ENGINE 276.9 AR01.10-P-2401EHV
MODEL 212 (except 212.067/080/088/095/195/267/280/288) with ENGINE 276.9
MODEL 218 (except 218.367/368/967/968) with ENGINE 276.9		 AR01.10-P-2401EL
MODEL 204.05/25/95 with ENGINE 276.9
MODEL 207 (except 207.38) with ENGINE 276.9		 AR01.10-P-2401FH
MODEL 172 with ENGINE 276 AR01.10-P-2401W
2 Detach transmission with torque converter ENGINE 276 in MODEL 172, 204, 207, 212, 218  
MODEL 212 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96)
MODEL 218 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500EV
MODEL 204.0/9 with ENGINE 276 with TRANSMISSION 722.96
MODEL 207.3, 212, 218 with ENGINE 276 with TRANSMISSION 722.96		 AR27.10-P-0500CWX
MODEL 204, 207 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96) AR27.10-P-0500CV
MODEL 172 with ENGINE 276 with TRANSMISSION 722.9 AR27.10-P-0500W
3 Secure engine to assembly stand Passenger car engine assembly stand  
4 Remove both cylinder heads Cylinder head on the right, model 212, 218 with engine 276.9 AR01.30-P-5780EL
Cylinder head on the right, model 204, 207 with engine 276.9 AR01.30-P-5780FH
Cylinder head on the left, model 172 with engine 276 AR01.30-P-5780W
Cylinder head on the right, model 207, 212, 218 with engine 276.8 AR01.30-P-5780ELS
Cylinder head on the left, model 212, 218 with engine 276.9 AR01.30-P-5770EL
Cylinder head on the left, model 204, 207 with engine 276.9 AR01.30-P-5770FH
Cylinder head on the left, model 172 with engine 276 AR01.30-P-5770W
Cylinder head on the left, model 207, 212, 218 with engine 276.8 AR01.30-P-5770ELS
5 Remove oil pan ENGINE 276.8 in MODEL 207, 212, 218 AR01.45-P-7500ELS
MODEL 212 (except 212.095/195), 218 with ENGINE 276.9 AR01.45-P-7500EL
MODEL 212.095/195 with ENGINE 276 AR01.45-P-7500EHV
MODEL 204, 207 with ENGINE 276.9 AR01.45-P-7500FHA
MODEL 172 with ENGINE 276 AR01.45-P-7500W
6 Remove oil pump MODEL 212, 218 with ENGINE 276 AR18.10-P-6020EL
MODEL 204, 207 with ENGINE 276 AR18.10-P-6020FH
MODEL 172 with ENGINE 276 AR18.10-P-6020W
7 Mark installation position on the connecting rod bearing caps (1) and connecting rods (2) IMPORTANT The connecting rod (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 (5) 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) For replacement of the piston rings (6a, 6b, 6c)  
  AR03.10-P-7311FH 
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 can occur otherwise.		  
Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
19 Check all power unit components for damage and wear and replace if necessary    
20 Check cylinder barrel    
IMPORTANT General information on inspecting cylinder walls AH01.00-P-0300-01A
IMPORTANT General information on inspecting cylinder walls AH01.00-P-0300-01AMG
INSTALLING Install     
21 Assign piston (5) to the respective cylinder bore When replacing the piston (5).  
  AR03.10-P-7021-03MM 
22 Lubricate piston pin (8) and connecting rod small end    
23 Align piston (5) and connecting rod (2) to 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 replacing the piston rings (6a, 6b, 6c) or the piston (5)  
  AR03.10-P-7311FH 
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 Rotate crankshaft so that connecting rod (2) is not touching connecting rod journal when inserting the piston (5) into cylinder bore.		  
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 Connecting rod bolt *BA03.10-P-1001-01E 
33 Turn crankshaft by hand and check for unobstructed movement of crank assembly    
34 Install oil pump MODEL 212, 218 with ENGINE 276 AR18.10-P-6020EL
MODEL 204, 207 with ENGINE 276 AR18.10-P-6020FH
MODEL 172 with ENGINE 276 AR18.10-P-6020W
35 Install oil pan ENGINE 276.8 in MODEL 207, 212, 218 AR01.45-P-7500ELS
MODEL 212 (except 212.095/195), 218 with ENGINE 276.9 AR01.45-P-7500EL
MODEL 212.095/195 with ENGINE 276 AR01.45-P-7500EHV
MODEL 204, 207 with ENGINE 276.9 AR01.45-P-7500FHA
MODEL 172 with ENGINE 276 AR01.45-P-7500W
36 Install both cylinder heads Cylinder head on the right, model 207, 212, 218 with engine 276.8 AR01.30-P-5780ELS
Cylinder head on the right, model 212, 218 with engine 276.9 AR01.30-P-5780EL
Cylinder head on the right, model 204, 207 with engine 276.9 AR01.30-P-5780FH
Cylinder head on the left, model 172 with engine 276 AR01.30-P-5780W
Cylinder head on the left, model 212, 218 with engine 276.9 AR01.30-P-5770EL
Cylinder head on the left, model 204, 207 with engine 276.9 AR01.30-P-5770FH
Cylinder head on the left, model 172 with engine 276 AR01.30-P-5770W
Cylinder head on the left, model 207, 212, 218 with engine 276.8 AR01.30-P-5770ELS
37 Detach engine from assembly stand    
38 Mount transmission with torque converter ENGINE 276 in MODEL 172, 204, 207, 212, 218  
MODEL 212 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96)
MODEL 218 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96)		 AR27.10-P-0500EV
MODEL 204.0/9 with ENGINE 276 with TRANSMISSION 722.96
MODEL 207.3, 212, 218 with ENGINE 276 with TRANSMISSION 722.96		 AR27.10-P-0500CWX
MODEL 204, 207 with ENGINE 276 with TRANSMISSION 722.9 (except 722.96) AR27.10-P-0500CV
MODEL 172 with ENGINE 276 with TRANSMISSION 722.9 AR27.10-P-0500W
39.1 Install engine with front axle carrier Engine 276 in model 204, 207, 212 with code M005 (4MATIC)  
ENGINE 276.8 in MODEL 212.067/099/167/168/267/299 AR01.10-P-2500ELS
MODEL 204.08/98, 207.38 with ENGINE 276.9 AR01.10-P-2500FH
MODEL 212.08/28 with ENGINE 276.9 AR01.10-P-2500ELB
39.2 Install engine with transmission Engine 276 in model 172, 204, 207, 212, 218 except code M005 (4MATIC)  
ENGINE 276.8 in MODEL 207 AR01.10-P-2401FT
ENGINE 276.8 in MODEL 212.061/065/165/261/265 AR01.10-P-2401ELS
MODEL 172 with ENGINE 276 AR01.10-P-2401W
MODEL 204.05/25/95 with ENGINE 276.9
MODEL 207 (except 207.38) with ENGINE 276.9		 AR01.10-P-2401FH
MODEL 212 (except 212.067/080/088/095/195/267/280/288) with ENGINE 276.9
MODEL 218 (except 218.367/368/967/968) with ENGINE 276.9		 AR01.10-P-2401EL
MODEL 212.095/195 with ENGINE 276.9 AR01.10-P-2401EHV
TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Number Designation ENGINE 276
BE03.10-P-1001-03A Connecting rod bolts Thread Ø   M 8X1
Shank length New mm 42, 5
Max. mm 43, 3
CONNECTING ROD

Number Designation ENGINE 276
BA03.10-P-1001-01E Connecting rod bolt Stage 1 Nm 5
Stage 2 Nm 25
Stage 3 ∠° 90
Fig 3: Identifying Tensioning Strap (000 589 04 14 00)
G09974064Courtesy 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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