Installing all the pistons with the connecting rod

NOTE: The description is provided only at one component. The procedure is the same for all other components.

Installing the piston with the connecting rod

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large 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 twisted by 120° each.

The contact points must not be aligned over the axis of piston pin (A) .

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

Ensure that spring (O2) does not overlap at contact point (1) .

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Insert connecting rod bearing shell (2) at the top in connecting rod (1) .
Apply a light coat of oil to the connecting rod bearing shell (2) .

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Coat the pistons (1) and piston rings lightly with oil.
Insert the piston (1) with the piston rings into special tool (connector) 0 495 373 (11 6 240) .
Screw special tool 2 463 755 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.
A large 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

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

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

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Screw the special tool (inlet guide) 2 463 755 into the large connecting rod eye if required.
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.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.

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

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Place the connecting rod bearing cap on the connecting rod so that the designations (1) match.

Replace screws (1) .
Parts: Screws

Tighten the bolts with the special tool 0 490 504 (00 9 120) .

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TIGHTENING TORQUE SPECIFICATIONS

Connecting rod bearing cap to connecting rod
Replace connecting rod bolts.	Tightening torque	20 Nm
	1. Angle of rotation	70°
	2. Angle of rotation	70°

Follow-up work

Refer to INSTALLING THE OIL DEFLECTOR .
Refer to INSTALLING OIL PUMP .
Refer to REFITTING OIL PAN .
Refer to INSTALLING STARTER MOTOR .
Refer to INSTALLING THE ACOUSTIC COVER FOR THE OIL SUMP .
Refer to REPLACING THE O-RING FOR THE BEARING BRACKET .
Refer to INSTALLING BEARING BRACKET .
Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
Refer to SEALING THE OIL DUCT .
Refer to CLEANING SEALING SURFACES .
Refer to INSTALLING THE CYLINDER HEAD GASKET .
Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
Refer to INSTALLING THE CYLINDER HEAD .
Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
Refer to DISASSEMBLING ALL SPECIAL TOOLS .
Refer to INSTALLING CHAIN TENSIONER .
Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING BOTH ACTUATORS .
Refer to PREPARING THE INJECTORS FOR INSTALLATION .
Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
Refer to INSTALLING HIGH PRESSURE PUMP .
Refer to INSTALLING FUEL DELIVERY LINE .
Refer to INSTALLING ALL SPARK PLUGS .
Refer to INSTALLING ALL IGNITION COILS .
Refer to INSTALLING CATALYTIC CONVERTER .
Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
Refer to INSTALLING LAMBDA OXYGEN SENSOR .
Refer to INSTALLING THE INTAKE PLENUM .
Refer to INSTALLING THE TANK VENT VALVE .
Refer to INSTALLING ACOUSTIC COVER AT REAR .
Refer to FILLING ENGINE OIL .
Refer to OPENING THE OIL FILLER CAP .
Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG .
Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .
Refer to INSTALLING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .