REP-TAT-P-1125-02 Installing all pistons with connecting rod

NOTE: The description is for one component only. The procedure is identical for all further components.

Installing piston with connecting rod

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
Major force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

Aligning piston rings

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Align the contact points of all piston rings rotated by 120° each.

Do not position contact points over axis of piston pin (A).

Piston ring	Alignment
Lower oil scraper ring (O3)	12 o'clock position (1)
Spring (O2)	4 o'clock position (2)
Upper oil scraper ring (O1)	8 o'clock position (3)
Middle piston ring (K2)	12 o'clock position (1)
Upper piston ring (K1)	4 o'clock position (2)

Make sure that the spring (O2) at the contact point (1) does not overlap.

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Coat the pistons (1) and piston rings lightly with oil.
Insert the pistons (1) with the piston rings into the connector 0 495 373 (11 6 240) .
Screw special tool 0 496 144 (11 8 860) on at large connecting rod eye (2).

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Align the piston so that the arrow (1) points to cylinder 1.
Insert the piston with the connecting rod into the special tool 0 495 373 (11 6 240) and guide it into the cylinder.

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
Major force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

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Push in piston by hand with only little force. Do not use striking tools.

Install the lower connecting rod bearing

Vacuum the connecting rod bearing shell and cracked surface (1) with a vacuum cleaner (2).

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Insert the connecting rod bearing shell (1) into the connecting rod bearing cap (2).
Apply a light coat of oil to the connecting rod bearing shell (1).

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If necessary, screw the inlet guide 0 496 144 (11 8 860) into the large connecting rod eye.
Pull the connecting rod up to the connecting rod bearing journal.

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NOTE: RISK OF DAMAGE
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
Engine damage may result from incorrectly installing bearing shells and bearing brackets.

Always install all bearing shells and bearing brackets in the same position from which they were removed.

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Attach the connecting rod bearing caps to the connecting rod until the designations (1) match.
Make sure that the connecting rod bearing (2) is attached to the same connecting rod that it was detached from.
A mixed installation of the connecting rod bolts (A) and (B) on a connecting rod bearing cap is not permissible.

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NOTE: TECHNICAL INFORMATION
When installing new connecting rod bolts, you must ensure that two connecting rod bolts are always used on one connecting rod bearing cap.
Mixed installation of various connecting rod bolts on one connecting rod bearing cap is not permitted.

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Replace screws (1).
Tighten the screws.
Make sure that the connecting rod bearing cap (2) rests completely on the connecting rod.

TIGHTEN TORQUES SPECIFICATIONS

Connecting rod bearing cap to connecting rod Replace screws.
Tighten screws crosswise.
Joining torque	20 Nm
1. Angle of rotation	70°
2. Angle of rotation	70°