Part 1
WM 131020 Removing and installing pistons and handling toolsTools
Technical values
Tools
Information
- All engine repairs must be carried out using only the specified tools.
- Only these tools have been tested and approved.
Tool overview:
Removing and installing special tools for pistons
Removing pistons
Removing pistons - cylinder bank 1-3
Information
- The specified positions relate to removing and installing components on the engine assembly support with the engine in a vertical position.
- Mark pistons in installation position using a water-resistant marker (e.g. Edding 750).
1. Unscrew screw plug (M30 x 1.5) -1- for removing piston pins.
1.1. Replace sealing ring.
Screw plug for removing/fitting piston pins
To remove a piston-pin circlip:
2. Use turning device 9773 to turn the crankshaft and vibration damper to the bottom dead centre position U 1/4 marking and lock at this position using a locating pin 9595/1 -1-.
Crankshaft position at BDC 1/4
WARNING
Preloaded or pressurised components
- Risk of eye injuries
- Risk of bruising
-> Wear personal protective gear.
-> Secure components to prevent them from falling off suddenly.
Information
- Special tool disassembly tool 9764 for removing piston-pin circlips must only be turned in a clockwise direction.
- Always hold the tool firmly with one hand when using it.
- Replace removed piston-pin circlips.
3. Slide special tool disassembly tool 9764 through the assembly bore. The groove for the hook on the circlip -arrow- must be at 9 o'clock position when the engine is positioned vertically.
Groove position for circlip hook (9 o'clock)
4. Disassembly tool 9764 must now be pushed into the circlip.
Positioning groove of special tool 9764 in hook on circlip
4.1. Carefully turn the tool to the left and right. You should feel resistance from the hook.
5. Tighten circlip with tool 9764. To do this, turn the hexagonal handle clockwise until you feel a certain amount of resistance.
Tightening circlip with tool
6. Keep the hexagonal handle -1- tight and turn the pipe -2- clockwise until you feel a certain amount of resistance. At the same time, the cheese head bolt will move horizontally to the left from position A in the guide groove.
Tool 9764 at position A
6.1. Hold the tool firmly at the pipe -2- and press it slightly against the piston. Slowly turn the hexagonal handle -1- using spring force until the cheese head bolt is at position B.
Tool 9764 at position B
6.2. Hold the hexagonal handle -1- firmly and turn the pipe -2- clockwise until you feel a certain amount of resistance. At the same time, the cheese head bolt will move horizontally to the left from position B in the guide groove.
Tool 9764 at stop ahead of position C
6.3. Hold the tool firmly at the pipe -2- and press it slightly against the piston. Slowly turn the hexagonal handle -1- using spring force until the cheese head bolt is at position C. The circlip engages in the tool with an audible click.
Tool 9764 at position C
6.4. Slowly pull the tool and circlip -1- out of the crankcase. Dispose of old circlips.
Pulling tool 9764 out of the crankcase
To remove a piston pin: Use interchangeable insert in accordance with the specified engine.
Disassembly tool 9777
Tool 9777 for removing/fitting piston pins
Interchangeable inserts for tool 9777
7. Disassembly tool 9777 must be pushed as far as it will go into the piston pin.
7.1. Hold the tool firmly at the hexagon -1- and turn the hexagon -2- anti-clockwise as far as it will go.
Sliding tool 9777 into piston pin
7.2. Pull out piston pin -1-. Inset shows the tensioned piston pin.
Removing piston pin
7.3. To loosen the piston pin, turn the rear hexagonal handle -2- clockwise until the pin can be removed.
Loosening tool 9777 on piston pin
To remove pistons:
8. Assembly aid 9783 must be inserted into the cylinder bore from the oil pan side. Then press out the piston (by tapping lightly on the handle with the ball of your hand).
8.1. Assign the correct piston pin to the piston immediately.
8.2. Fit assembly aid 9795 -1- (rubber sleeve) on the connecting rod to protect the cylinder liner.
Protective sleeves 9795 for connecting rods 1-3
9. Turn the crankshaft to the bottom dead centre position U 2/5 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1-.
U 2/5 marking on vibration damper
9.1. Repeat steps 3 to 8 for removing piston 2.
10. Turn the crankshaft to the bottom dead centre position U 3/6 marking at the vibration damper and lock at this position using a locating pin (tool 9595/1) -1-.
U 3/6 marking on vibration damper
10.1. Repeat steps 3 to 8 for removing piston 3.
11. Check piston for signs of wear.
-> 1310IN Piston wear, weight groups and identification markings [1][2]Piston, Engine.