AR03.10-P-7021A
ENGINE
111

Remove/install piston

18.11.08

Remove pistons

P03.10-0207-06

P03.10-0208-09

Modification notes
24.9.01

Value modified from 45 Nm to 5 Nm

Value modified in BA03.10-P-1001-01H onengine 111
Stage 1

*BA03.10-P-1001-01HRemoving
1
2

Remove cylinder head
Remove oil pan© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021a, Remove/install piston
ENGINE 111

Engine 111.940/ 960 in model 124
Engine 111.920/921/941/945 /961/974 inmodel 202
Engine 111.946 in model 170
Engine 111.945 in model 208
Engine 111.977 in model 163
Engine 111 in model 210

AR01.30-P-5800A
AR01.45-P-7500A

AR01.45-P-7500AG
AR01.45-P-7500B
Page 1 of 4

Engine 111.943/973 in model 170 and111.944/975 in model 202
Engine 111.944/975 in model 208

AR01.45-P-7500E

3.1
4.1
5

Remove oil pump
Remove oil deflector plate
Unscrew connecting rod bearing cap (1)6Remove connecting rod (2) together withpistons (4) by lifting up and out

In the case of a worn piston the stampedon travel direction arrow or color dots are nolonger visible so the direction of travel should
be drawn on the piston.

7Use a screwdriver to press out piston pinretainer (5)8Press out piston pin (6)9Check vertical clearance of piston rings
InstallDo not damage piston. Use a clean cloth
as a baseif necessary, for example for engine repair
Repair connecting rod
AR03.10-P-6111A*BE03.10-P-1002-02A

10

Assigning a standard dimension piston to acylinder bore

1112

Oil piston pin (6) and connecting rod bush
Assemble piston (4) and connecting rod (2)1314Push in piston pin (6) by hand.
Insert piston pin retainer (5) into the groove(arrow) on the piston.
Oil cleaned cylinder bores, connecting rod
bearing journals, connecting rod bearing
shells and pistons (4)Piston with an open combustion chamber

15

16
17

18

AR18.10-P-6020HG
AR03.10-P-7021-01A

Connecting rod (2) and connecting rod
bearing cap (1) are marked together (arrow).

When installing new standard size pistons. AR03.10-P-7021-02A
Install new piston into used engine only if thecylinder bore does not have any abnormal
wear, is within the dimensional tolerances forcylinder shape and roundness and the honing
is visible and undamaged; if required.
Measure cylinder bores
AR01.40-P-9201A
Engine 111
BT03.10-P-0001-01A
Assemble piston and connecting rod insuch a way that the arrow or color dot on thepiston crown points in the direction of travel.
The marking and the retaining grooves in theconnecting rod are located on the left (at theinlet side).
The elevation (4a) on one of the piston bolt
hubs must point against the direction of travel.

Install connecting rod bearing shell with oil
drilling in the connecting rod (2), otherwise theconnecting rod bush will not be lubricated.

Fit on tensioning strap (7) for piston rings and*000589041400
tensionInstall piston (4) with arrow or colored dot
The elevation (4a) on one of the piston
facing in direction of travel
bolt hubs must point against the direction oftravel.
Screw on connecting rod bearing cap (1)Screw connecting rod bearing cap (1) andconnecting rod (2) with the markings (arrows)
pointing toward each other.
*BA03.10-P-1001-01H

19
20

Rotate crankshaft and inspect clearance
Measure piston projection

21.1
22.1
23

Install oil deflector plate
Install oil pump
Installing oil pan24

Engines with oil baffle

Install cylinder headIf piston projection is not correct,
determine cause and specify appropriate
repair measure.

Engine 111.940/ 960 in model 124
Engine 111.920/921/941/945 /961/974 inmodel 202
Engine 111.946 in model 170
Engine 111.945 in model 208
Engine 111.977 in model 163
Engine 111 in model 210
Engine 111.943/973 in model 170 and
111.944/975 in model 202
Engine 111.944/975 in model 208*BE03.10-P-1001-02A

AR03.10-P-7021-01A
AR18.10-P-6020HG
AR01.45-P-7500A

AR01.45-P-7500AG
AR01.45-P-7500B
AR01.45-P-7500E

AR01.30-P-5800A

Test specifications for pistons© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021a, Remove/install piston
ENGINE 111

Page 2 of 4

NumberDesignation

BE03.10-P-1001-02A

Piston projects or stands
backBE03.10-P-1002-02A

Piston ring verticalclearance

Engine 111.920
up to 04/94(Quench zone
combustionchamber)=9.8

Engine 111.920
as of 04/94 withSA 012.496/08(Opencombustion
chamber, fueloptimized)=8.8

Engine 111.920
as of 04/94(opencombustionchamber)
=9.8

mm

+0.57/ +0.93-0.77/ -1.13-0.77/ -1.13

Groove 1mm0.03 to 0.06

0.03 to 0.06

0.03 to 0.06

Groove 2mm

0.01 to 0.05

0.01 to 0.05

0.01 to 0.05

Groove 3mm

0.02 to 0.06

0.02 to 0.06

0.02 to 0.05

Engine 111.940/
941(Quench zone
combustionchamber)=9.6

Engine 111.940/
941 with
SA 012.496/02(Quench zone
combustion
chamber, fueloptimized)=8.5

Engine111.943/944/947(Quench zone
combustionchamber)
=8.5

mm

+0.42/ +0.78+0.42/ +0.78+0.42/ +0.78

Groove 1mm

0.03 to 0.06

0.03 to 0.06

0.03-0.06

Groove 2mm

0.01 to 0.05

0.01 to 0.05

0.01-0.05

Groove 3mm

0.01 to 0.05

0.02 to 0.06

0.02-0.06

Engine 111.960/
961 with
SA 012.400/05(Quench zone
combustionchamber)=9.8

Engine 111.960/
961 with
SA 012.496/03(Quench zone
combustion
chamber, fueloptimized)=8.5

Engine 111.970/
974/977(opencombustionchamber)
=10.4

mm

+0.62/ +0.98+0.62/ +0.98-1.02/ -1.38

Groove 1mm

0.03-0.06

0.03-0.06

0.03-0.06

Groove 2mm

0.01-0.05

0.01-0.05

0.01-0.05

Test specifications for pistons
NumberDesignation

BE03.10-P-1001-02A

Piston projects or stands
backBE03.10-P-1002-02A

Piston ring verticalclearance

Test specifications for pistons
NumberDesignation

BE03.10-P-1001-02A

Piston projects or stands
backBE03.10-P-1002-02A

Piston ring verticalclearance© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021a, Remove/install piston
ENGINE 111

Page 3 of 4Groove 3mm0.02-0.06

0.02-0.06

0.02-0.06

Engine 111.970(open
combustionchamber, fueloptimized)=8.8

Engine111.973/975(Quench zone
combustionchamber)=8.8

Engine111.973/975(opencombustionchamber)=8.8

mm-1.02/ -1.38+0.62/ +0.98-1.02/ -1.38

Groove 1mm

0.03-0.06

0.03-0.06

0.03-0.06

Groove 2mm

0.01-0.05

0.01-0.05

0.01-0.05

Groove 3mm

0.02-0.06

0.02-0.06

0.02-0.06

Test specifications for pistons
NumberDesignation

BE03.10-P-1001-02A

Piston projects or stands
backBE03.10-P-1002-02A

Piston ring verticalclearance

Connecting rod
NumberDesignation

BA03.10-P-1001-01H

Connecting rod screw(stretch shank)Engine111

Stage 1Nm

5

Stage 2

Nm

25

Stage 3°90000 589 04 14 00
Tensioning strap© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021a, Remove/install piston
ENGINE 111

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