Installing all pistons with connecting rod

Installing piston with connecting rod 

Aligning piston rings 

Aligning piston rings 

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

  The piston ring gaps must not be positioned in line with the axis of the 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)
  Central piston ring (K2)	12 o'clock position (1)
  Upper piston ring (K1)	4 o'clock position (2)

• Make sure that the spring (O2) does not overlap the piston ring gap (1).

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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. 
  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 

• 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. 
  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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• 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.

Follow-up work 

• Refer to INSTALLING THE OIL DEFLECTOR .
• Refer to INSTALLING THE OIL VACUUM PUMP .
• Refer to REFITTING ENGINE OIL PAN .
• Refer to SEALING THE OIL DUCT .
• Refer to CLEANING SEALING SURFACES .
• Refer to INSTALLING THE CYLINDER HEAD .
• Refer to ATTACHING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
• Refer to BLOCKING THE CAMSHAFTS .
• Refer to INSTALLING THE INTAKE ADJUSTER .
• Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
• Refer to PRELOAD TIMING CHAIN .
• Refer to TIGHTENING THE VANOS CENTRAL VALVE .
• Refer to CRANKING ENGINE TWICE (AUTOMATIC TRANSMISSION) .
• Refer to DISASSEMBLING ALL SPECIAL TOOLS .
• Refer to INSTALLING THE CYLINDER HEAD COVER (ENGINE REMOVED) .
• Refer to INSTALLING BOTH ACTUATORS (ENGINE REMOVED) .
• Refer to PREPARING FOR THE INSTALLATION OF THE HIGH PRESSURE PUMP .
• Refer to INSTALLING HIGH PRESSURE PUMP .
• Refer to PREPARING THE INJECTORS FOR INSTALLATION .
• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING THE IGNITION COILS .
• Refer to INSTALLING THE INTAKE PLENUM .
• Refer to INSTALLING THE TANK VENT VALVE .
• Refer to INSTALLING FRONT ENGINE ENCAPSULATION .
• Refer to INSTALLING THE COOLANT FEED LINE FOR THE EXHAUST TURBOCHARGER (COOLANT RETURN LINE REMOVED) .
• Refer to INSTALLING THE COOLANT RETURN LINE FOR THE EXHAUST TURBOCHARGER (AUXILIARY COOLANT PUMP REMOVED) .
• Refer to TIGHTENING THE OIL DRAIN PLUG .
• Refer to TOPPING UP THE MOTOR OIL .
• Refer to REMOVING ENGINE FROM ASSEMBLY STAND. .
• Refer to INSTALLING THE RIGHT ENGINE MOUNTING BRACKET .