Removing all pistons with connecting rod
CAUTION:
Component with heavy weight.
Injury hazard!
Injury hazard!
- Note component's center of gravity.
- Support component using a jack.
- Secure component against falling off the jack.
CAUTION:
On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!
Injury hazard!
- Wear suitable personal protective equipment.
- Before performing any installation work, allow cooling system to cool down to less than 40°C.
- Note warnings on cylinder head cover.
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Preliminary work
- Refer to REMOVING ENGINE .
- Refer to INSTALLING THE ENGINE ON THE ASSEMBLY STAND
- Refer to RELEASING THE OIL DRAIN PLUG .
- Refer to TIGHTENING THE OIL DRAIN PLUG .
- Refer to REMOVING ALL SPARK PLUGS .
- Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
- Refer to REMOVE HIGH PRESSURE PUMP .
- Refer to REMOVING THE RAIL WITH INJECTORS .
- Refer to REMOVING BOTH ACTUATORS .
- Refer to REMOVING THE CYLINDER HEAD COVER .
- Refer to REMOVE TANK VENT VALVE .
- Refer to REMOVING THE INTAKE PLENUM .
- Refer to REMOVE THE HEAT SHIELD AT THE CYLINDER HEAD
- Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to REMOVE THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to REMOVE THE COOLANT FEED LINE FOR THE EXHAUST GAS TURBOCHARGER .
- Refer to REMOVING THE THERMOSTAT FROM THE TRANSMISSION OIL LINES .
- Refer to REMOVING THE HOLDER FOR THE THERMOSTAT ON THE TRANSMISSION OIL LINE .
- Refer to BLOCKING ENGINE IN TDC FIRING POSITION
- Refer to REMOVING CHAIN TENSIONER .
- Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING INTAKE ADJUSTER .
- Refer to REMOVE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVE THE TEST GAUGES FOR SECURING THE CAMSHAFTS .
- Refer to REMOVING THE CYLINDER HEAD .
- Refer to REMOVING THE CYLINDER HEAD GASKET .
- Refer to REMOVING THE ACOUSTIC COVER OF THE OIL SUMP .
- Refer to REMOVING STARTER MOTOR .
- Refer to REMOVING FLYWHEEL .
- Refer to REMOVE FRONT AXLE DIFFERENTIAL .
- Refer to REMOVE BEARING BRACKET .
- Refer to REMOVE OIL SUMP .
- Refer to REMOVE THE OIL VACUUM PUMP .
- Refer to REMOVING THE OIL DEFLECTOR
NOTE:
The description is for one component only. The procedure is identical for all further components.
Removing the piston with connecting rod
NOTE:
TECHNICAL INFORMATION
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
NOTE:
TECHNICAL INFORMATION
The connecting rods of the engine are balanced and matched to each other.
A single connecting rod is not permitted to be replaced. Always replace all connecting rods.
The connecting rods of the engine are balanced and matched to each other.
A single connecting rod is not permitted to be replaced. Always replace all connecting rods.
Detach the lower connecting rod bearing
NOTE:
RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.
- Carefully shift the piston and connecting rod in the engine block.
- Turn the crankshaft until the connecting rod bearing journal (1) reaches a vertical position.
NOTE:
RISK OF DAMAGE
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.
- Always install all bearing shells and bearing brackets in the same position from which they were removed.
- Unscrew the connecting rod bolts (1).
- Remove the connecting rod bearing cap (2) and put to one side in the correct order.
Make sure that the connecting rod bearing cap (2) can be re-exchanged in the correct position.
NOTE:
RISK OF DAMAGE
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.
- Always install all bearing shells and bearing brackets in the same position from which they were removed.
- Remove the connecting rod bearing (1).
Make sure that the connecting rod bearing (1) can be re-exchanged in the correct position.
- Screw special tool 0 496 144 (11 8 860)
in at large connecting rod eye.
- Press piston (1) with connecting rod up and out of crankcase.
