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Old 01-02-2026, 01:35 PM
vox_incognita vox_incognita is offline
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Join Date: Mar 2003
Posts: 554
So going through the manual,

-the original type of pistons in w115 240d would look like :

https://www.peachparts.com/shopforum/attachments/diesel-discussion/94422d1312305275-616-rebuild-options-img_0507.jpg

They are used with flat tip prechambers, the one that you showed in your photo.

Later MB introduce the star-shaped combustion chamber pistons with two different type of recesses - flat and rounded(for the so called "uprated engines" in the manual) :


Flat tip PC's are OK with :
-pistons with round shaped comb.chamber (as originally)
-and star shaped Cchambers having the flat recess (type C)

..........

Round tip PC are to be used with star shaped chamber with rounded recess (type D) .
They should not be used with star shaped , flat recess chambers (Type C)
...or with the round combustion chamber cavities (like the older type om615/616). These are only in om615/616 context !

Click image for larger version

Name:	recesses - Copy.png
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However, the way I read the manual ,the flat recessed star chambers (Type C) are applicable only to om615's pistons .

So your PC's seem to be unsuitable for the NE pistons that came with the block (because they probably have the rounded recess-and that is IF the star-shaped flat recess of type C ever existed in 616-617 pistons ).

I tried to look closely at the your photos,also checked some other,like this genlteman here:

https://www.flickr.com/photos/govert1970/albums/72157625987974204/

Note that he upgraded to the round tip prechambers. The new pistons look to have a rounded "star" recess(type D)...but light and photo angle play tricks...

Also , the NPR catalog lists only 1 type of om 616-617 pistons, page 202 :
https://www.npr-europe.com/wp-content/uploads/2024/08/P7-Katalog.pdf

They probably went with the most "popular" option, the "rounded" recess star (for later type, rounded tip PC's)...


Also, some pics from YT of a guy restoring a w115 om615 using "star"and flat recess pistons .

Click image for larger version

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Note that he is keeping the original flat tip PC's .
Click image for larger version

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Check first the type of recesses yours have...but judging by the manuf.catalog they're probably rounded.


A thread with part #'s :

http://www.peachparts.com/shopforum/mercedes-parts-reference-library/315201-om616-916-extreme-rebuild-parts-list.html

http://www.peachparts.com/shopforum/diesel-discussion/170391-different-type-prechambers.html

6160100152 - om616 prechamber , round tip, 616/01 marked .

Well...that's what I could gather . Hope that someone who's been through it would chime in.
Note the star shape in the Service manual and the currently offered pistons differ ...hm...
Attached Files
File Type: pdf 615-6-7 pistons1.pdf (683.0 KB, 52 views)
File Type: pdf 615-6-7 pc 1-5.pdf (427.1 KB, 44 views)

Last edited by vox_incognita; 01-02-2026 at 01:54 PM.
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