AR03.10-P-7021B
ENGINE604, 605, 606

Remove/install piston

6.8.10P03.10-0223-06

P03.10-0224-09

Removing
1.1
2

Remove engine
Remove cylinder head3

Remove oil pan

45
6Remove oil pump
Remove oil deflector plate
Unscrew connecting rod bearing cap (1)© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021b, Remove/install piston
ENGINE 604, 605, 606

Model 463 with engine 606.964
Model 124, 140, 202, 210
Model 463 with engine 606.964
Engine 604, 605 in model 124
Engine 604, 605 in model 202
Engine 605, 606 in model 210
Engine 606.961 in model 140
Engine 604 in model 210
Engine 606.964 in model 210

AR01.10-P-2400GG
AR01.30-P-5800HA
AR01.30-P-5800GG
AR01.45-P-7500HA
AR01.45-P-7500C
AR01.45-P-7500D
AR01.45-P-7500GG
AR18.10-P-6020HAConnecting rod (2) and connecting rod
bearing cap (1) are marked together (arrow).
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7

Remove connecting rod (2) together withpistons (4) by lifting up and out

If the pistons are worn, the direction of
travel of arrows may no longer be visible
because of carbon deposits. For this reason,
remove carbon deposits to render direction oftravel arrow visible.

8Use a screwdriver to press out piston pinretainer (5)Do not damage piston. Use a clean cloth
as a base

9Press out piston pin (6)Install1011

Oil piston pin (6) and connecting rod bush
Assemble piston (4) and connecting rod (2)1213Push in piston pin (6) by hand.
Insert piston pin retainer (5) into the groove(arrow) on the piston.
Oil cleaned cylinder bores, connecting rod
Do not mix up top and bottom connecting
bearing journals, connecting rod bearing
rod bearing shells
shells and pistons (4)Fit on tensioning strap (7) for piston rings and*000589041400
tensionInstall piston (4) with arrow pointing in
direction of travel
Check connecting rod bolts
AR03.10-P-6111-01A*BE03.10-P-1001-03A
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-1001-01B

1415
16
17
18

19
20
21
22

23

Rotate crankshaft and inspect clearance
Install oil deflector plate
Install oil pump
Installing oil panMeasure piston projection

24

Install cylinder head

25.1

Install engine

Install piston with arrow pointing in
direction of travel.
The marking and the retaining lugs in theconnecting rod are located on the left (at theinlet side).

Engine 604, 605 in model 124
Engine 604, 605 in model 202
Engine 605, 606 in model 210
Engine 606.961 in model 140
Engine 604 in model 210
Engine 606.964 in model 463
Install cylinder head gasket of standard
thickness or cylinder head gasket of repair
thickness (1.85 mm thick) depending on
piston projection

Model 124, 140, 202, 210
Model 463 with engine 606.964
Model 463 with engine 606.964

AR03.10-P-6111-02A
AR03.10-P-7021-01A
AR18.10-P-6020HA
AR01.45-P-7500HA
AR01.45-P-7500C
AR01.45-P-7500D
AR01.45-P-7500GG
AR03.10-P-7041-01A*BE03.10-P-1001-02B*BE03.10-P-1002-02B
AR01.30-P-5800HA
AR01.30-P-5800GG
AR01.10-P-2400GG

Test specifications for pistons
NumberDesignation

BE03.10-P-1001-02B

Piston projection (a) with new
crankcasemmSee picture
BE03.10-P-1002-02B

Piston projection (a) with machined
crankcasemmSee picture

Engine604.910/912

Engine604.915/917

0.735 to 0.965

0.785 to 1.015

AR03.10-P-7041-01A

AR03.10-P-7041-01A

0.835 to 1.015

0.985 to 1.215

AR03.10-P-7041-01A

AR03.10-P-7041-01A

Engine605.91/96

Engine606.91/96

Test specifications for pistons
NumberDesignation© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021b, Remove/install piston
ENGINE 604, 605, 606

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BE03.10-P-1001-02B

Piston projection (a) with new
crankcasemmSee picture
BE03.10-P-1002-02B

Piston projection (a) with machined
crankcasemmSee picture

0.785 to 1.015

0.785 to 1.015

AR03.10-P-7041-01A

AR03.10-P-7041-01A

0.985 to 1.215

0.985 to 1.215

AR03.10-P-7041-01A

AR03.10-P-7041-01A

Test specifications for connecting rod bolts
NumberDesignation

Engine604, 605, 606

BE03.10-P-1001-03A

Connecting rod bolts

Thread dia.

M

Shank length

9 1Newmm

51.7...52.3

max.

mm

52.9

Connecting rod
NumberDesignation

BA03.10-P-1001-01B

Connecting rod
screw (stretchshank)Engine604, 605,606

Stage 1Nm40Stage 2°90000 589 04 14 00
Tensioning strap© Daimler AG, 8/7/24, L/10/16, ar03.10-p-7021b, Remove/install piston
ENGINE 604, 605, 606

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