AR03.10-P-7021A Remove/install pistons 27.7.

94

ENGINE 111

Remove pistons

P03.10-0207-06

P03.10-0208-09

Modification notes

24.9.01 Value changed from 45 Nm to 5 Nm Value changed in BA03.10-P-1001-01H on *BA03.10-P-1001-01H

engine 111
Stage 1

e Remove
1 Remove cylinder head AR01.30-P-5800A

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 2 Remove oil pan Engine 111.940/960 in model 124 AR01.45-P-7500A
Engine 111.920/921/941/945 /961/974 in model
202
Engine 111.946 in model 170
Engine 111.945 in model 208
Engine 111.977 in model 163 AR01.45-P-7500AG
Engine 111 in model 210 AR01.45-P-7500B
Engine 111.943/973 in model 170 and AR01.45-P-7500E
111.944/975 in model 202
Engine 111.944/975 in model 208
3.1 Remove oil pump AR18.10-P-6020HG

4.1 Remove oil deflector plate Engines with oil deflector plate AR03.10-P-7021-01A

5 Unscrew conrod bearing cap (1) p Conrod (2) and conrod bearing cap (1) are
marked together (arrow)
6 Lift conrod (2) up and out together with piston (4) p If the pistons are worn, the direction-of-travel
arrows or colored dots stamped on the pistons
are no longer visible, for this reason mark
direction of travel on piston.
7 Use a screwdriver to press out piston pin p Do not damage piston. Use a clean cloth as
retainer (5) a base
8 Press out piston pin (6) If necessary, e.g. for repairing engine
Repairing conrod AR03.10-P-6111A

9 Check side clearance of piston rings *BE03.10-P-1002-02A

d Install
10 Assign standard size piston to cylinder bore i When installing new standard size pistons. AR03.10-P-7021-02A
Install new pistons into used engines only if the
cylinder bore does not have any abnormal wear,
is within the dimensional tolerances for cylinder
shape and roundness and the honing is visible
and undamaged, if necessary
Measure cylinder bores AR01.40-P-9201A
k Piston with open combustion chamber Engine 111 BT03.10-P-0001-01A

11 Oil piston pin (6) and conrod bush

12 Assemble piston (4) and conrod (2) i Assemble piston and conrod so that the
arrow or colored dot on piston crown is pointing
in direction of travel.
The marking and the retaining lugs in the conrod
are located on the left (at the inlet side).
The shoulder (4a) on one of the piston pin hubs
must face away from the direction of travel.
13 Push in piston pin (6) by hand.
14 Insert piston pin retainer (5) into the groove
(arrow) on the piston.
15 Oil cleaned cylinder bores, conrod bearing p Install conrod bearing shell with oil hole in
journals, conrod bearing shells and the conrod (2), otherwise the conrod bush will
pistons (4) not be lubricated.
16 Fit on tensioning strap (7) for piston rings and l *000589041400
tension
17 Install piston (4) with arrow or colored dot facing p The shoulder (4a) on one of the piston pin
in direction of travel hubs must point in the opposite direction.
18 Screw on conrod bearing cap (1) p Screw conrod bearing cap (1) and conrod
(2) with the markings (arrows) pointing toward
each other.
n *BA03.10-P-1001-01H

19 Rotate crankshaft and inspect for clearance

20 Measure piston projection i If piston projection is not correct, determine *BE03.10-P-1001-02A
cause and specify appropriate repair measure.
21.1 Install oil deflector plate AR03.10-P-7021-01A

22.1 Install oil pump AR18.10-P-6020HG

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 23 Install oil pan Engines 111.940/960 in model 124 AR01.45-P-7500A
Engines 111.920/921/941/945/961/974 in model
202
Engine 111.946 in model 170
Engine 111.945 in model 208
Engine 111.977 in model 163 AR01.45-P-7500AG
Engine 111 in model 210 AR01.45-P-7500B
Engine 111.943/973 in model 170 and AR01.45-P-7500E
111.944/975 in model 202
Engines 111.944/975 in model 208
24 Install cylinder head AR01.30-P-5800A

Test values for pistons

Number Designation Engine 111.920 Engine 111.920 Engine 111.920

up to 04/94 as of 04/94 with as of 04/94
(Quench zone SA 012.496/08 (open
combustion (Open combustion
chamber) combustion chamber)
=9.8 chamber, fuel- =9.8
optimized)
=8.8

BE03.10-P-1001-02A Piston projects or stands mm +0.57/+0.93 -0.77/-1.13 -0.77/-1.13

back

BE03.10-P-1002-02A Piston ring side clearance Groove 1 mm 0.03-0.06 0.03-0.06 0.03-0.06

Groove 2 mm 0.01-0.05 0.01-0.05 0.01-0.05

Groove 3 mm 0.02-0.06 0.02-0.06 0.02-0.05

Test values for pistons

Number Designation Engine 111.940/ Engine 111.940/ Engine

941 941 with 111.943/944/947
(Quench zone SA 012.496/02 (Quench zone
combustion (Quench zone combustion
chamber) combustion chamber)
=9.6 chamber, fuel- =8.5
optimized)
=8.5

BE03.10-P-1001-02A Piston projects or stands mm +0.42/+0.78 +0.42/+0.78 +0.42/+0.78

back

BE03.10-P-1002-02A Piston ring side clearance Groove 1 mm 0.03-0.06 0.03-0.06 0.03-0.06

Groove 2 mm 0.01-0.05 0.01-0.05 0.01-0.05

Groove 3 mm 0.01-0.05 0.02-0.06 0.02-0.06

Test values for pistons

Number Designation Engine 111.960/ Engine 111.960/ Engine 111.970/

961 with 961 with 974/977
SA 012.400/05 SA 012.496/03 (open
(Quench zone (Quench zone combustion
combustion combustion chamber)
chamber) chamber, fuel- =10.4
=9.8 optimized)
=8.5

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 BE03.10-P-1001-02A Piston projects or stands mm +0.62/+0.98 +0.62/+0.98 -1.02/-1.38
back

BE03.10-P-1002-02A Piston ring side clearance Groove 1 mm 0.03-0.06 0.03-0.06 0.03-0.06

Groove 2 mm 0.01-0.05 0.01-0.05 0.01-0.05

Groove 3 mm 0.02-0.06 0.02-0.06 0.02-0.06

Test values for pistons

Number Designation Engine 111.970 Engine Engine

(open 111.973/975 111.973/975
combustion (Quench zone (open
chamber, fuel- combustion combustion
optimized) chamber) chamber)
=8.8 =8.8 =8.8

BE03.10-P-1001-02A Piston projects or stands mm -1.02/-1.38 +0.62/+0.98 -1.02/-1.38

back

BE03.10-P-1002-02A Piston ring side clearance Groove 1 mm 0.03-0.06 0.03-0.06 0.03-0.06

Groove 2 mm 0.01-0.05 0.01-0.05 0.01-0.05

Groove 3 mm 0.02-0.06 0.02-0.06 0.02-0.06

n Conrod

Number Designation Engine 111

BA03.10-P-1001-01H Conrod screw 1st stage NM 5

(stretch shank)
Step 2 NM 25
Step 3 ° 90

000 589 04 14 00

Tensioning strap

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