Installing all the pistons with the connecting rod

Installing the piston with the connecting rod 

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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Follow-up work 

• Refer to INSTALLING THE OIL DEFLECTOR .
• Refer to INSTALLING THE OIL VACUUM PUMP .
• Refer to REFITTING SUMP .
• 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 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 ENGINE VENTILATION LINE .
• 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 .