Installing piston with connecting rod
NOTE:
TECHNICAL INFORMATION
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
NOTE:
TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage.
The work must be performed with vehicle care to prevent component damage.
NOTE:
The description is provided only at one component. The procedure is the same for all other components.
Aligning piston rings
- 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) Central piston ring (K2) 12 o'clock position (1) Upper piston ring (K1) 4 o'clock position (2) - Make sure that the contact point on the oil scraper ring does not overlap.
- Permitted combinations of connecting rod bearing shells
(1) with N63T3:
- Red - Blue
- Green - Yellow
- Permitted combinations of connecting rod bearing shells
(1) with S63T4:
- Green - Brown
- Insert the connecting rod bearing shell (1) into the connecting rod bearing cap and secure it with the retaining lugs (arrows).
- Insert the connecting rod bearing shell (1) into the connecting rod and secure it with the retaining lugs (arrows).NOTE: TECHNICAL INFORMATION
Maintain conditions of absolute cleanliness. - Do not clean the crack surfaces (1) with compressed air.
- Before assembling new connecting rods, vacuum them off in the arrow direction using a commercial vacuum cleaner (2).
- Screw special tools 2 249 164
into the thread in the area (1) of the connecting rod.NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage. - The connecting rod and connecting rod bearing cap are identified by the same matching letters (1) and must not
be mixed up.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.
- Position the piston (1) and connecting rod at the crankcase.
- Arrows (1) on the piston and connecting rod bearing cap must point in the driving direction toward the timing chain drive (2).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.
- Press special tool 0 494 310 (11 7 280)
(2) far enough together that the piston (1) can be installed in the crankcase.
The piston rings must not snag!
- Rotate crankshaft at central bolt if necessary.
- Remove special tools 2 249 164
.
- Position the crankshaft (2).NOTE: TECHNICAL INFORMATION
The work must be performed with vehicle care to prevent component damage. - Install the connecting rod bearing cap in such a way that the matching letters (3) are on the same side.
- Tighten connecting rod bolt using special tool 0 490 504 (00 9 120).
TIGHTENING TORQUE SPECIFICATIONS
| Connecting rod bolts, for new connecting rod | ||
|---|---|---|
| M9x1.25 Screw. Suction off crack surfaces. |
1. Tightening torque | 6 Nm |
| 2. Tightening torque | 20 Nm | |
| 3. Tightening torque | 30 Nm | |
| 4. Angle of rotation | 75° | |
TIGHTENING TORQUE SPECIFICATIONS
| Screw connection, for new connecting rod bolts only | ||
|---|---|---|
| M9x1.25 Replace screws. Suction off crack surfaces. | 1. Tightening torque | 6 Nm |
| 2. Tightening torque | 20 Nm | |
| 3. Tightening torque | 30 Nm | |
| 4. Angle of rotation | 75° | |
| 5. Unscrew all bolts. | 180° | |
| 6. Tightening torque | 5 Nm | |
| 7. Tightening torque | 20 Nm | |
| 8. Tightening torque | 30 Nm | |
| 9. Angle of rotation | 75° | |
| 10. Unscrew all bolts. | 180° | |
| 11. Tightening torque | 5 Nm | |
| 12. Tightening torque | 20 Nm | |
| 13. Tightening torque | 30 Nm | |
| 14. Angle of rotation | 75° | |
Checking the side clearance of the connecting rod bearing
- Install special tool 0 493 143 (11 6 250) on the crankcase.
- Press both connecting rods (1) up to the stop.
- Set dial gauge 0 493 143 (11 6 250) to 0.
- Press both connecting rods (1) to the stop and read out the values.
Follow-up work
- Refer to INSTALLING THE UPPER OIL SUMP SECTION .
- Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
- Refer to INSTALLING THE ENGINE MOUNT .
- Refer to FASTENING AIR CONDITIONING COMPRESSOR .
- Refer to INSTALLING OIL PUMP .
- Refer to INSTALL THE LOWER OIL PAN SECTION .
- Refer to INSTALLING RIGHT CYLINDER HEAD .
- Refer to INSTALLING BOTH VANOS ADJUSTERS (CYLINDER HEAD DISASSEMBLY BANK 1) .
- Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
- Refer to REMOVE RIGHT CYLINDER HEAD COVER .
- Refer to INSTALLING WIRING HARNESS SECTION FOR IGNITION SYSTEM OF BANK 1 .
- Refer to SECURING THE WIRING HARNESS SECTION FOR THE INTEGRATED POWER SUPPLY MODULE .
- Refer to INSTALLING RIGHT HIGH PRESSURE PUMP .
- Refer to INSTALLING THE HEAT SHIELD OF THE CRANKCASE VENTILATION OF CYLINDERS 1 TO 4 .
- Refer to INSTALLING FUEL DELIVERY LINE .
- Refer to SECURING THE FUEL SUPPLY LINE ON THE LEFT .
- Refer to SECURING COOLANT LINES FOR THE EXHAUST TURBOCHARGERS .
- Refer to INSTALL RAIL OF CYLINDER BANK 1 .
- Refer to INSTALLING RAIL ON BANK 2 .
- Refer to INSTALLING THE IGNITION COILS OF CYLINDERS 5 AND 6 .
- Refer to INSTALLING IGNITION COILS OF CYLINDER BANK 1 .
- Refer to INSTALLING THE LEFT THROTTLE BODY .
- Refer to INSTALLING ALTERNATOR .
- Refer to INSTALL DRIVE BELT .
- Refer to INSTALLING THE LEFT CYLINDER HEAD .
- Refer to INSTALLING BOTH LEFT VANOS ADJUSTERS (CYLINDER HEAD INSTALLATION CYLINDER BANK 2) .
- Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
- Refer to INSTALLING HEAT SHIELD ON THE BOTTOM .
- Refer to INSTALLING FRONT HEAT SHIELD .
- Refer to INSTALLING BOTH EXHAUST MANIFOLDS .
- Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 5 TO 8 .
- Refer to INSTALLING THE HEAT SHIELD OF THE CYLINDER HEAD COVER FOR CYLINDERS 1 TO 4 .
- Refer to INSTALLING THE LEFT CYLINDER HEAD COVER .
- Refer to INSTALLING LEFT AND RIGHT EXHAUST TURBOCHARGERS .
- Refer to INSTALLING WIRING HARNESS SECTION FOR IGNITION SYSTEM OF BANK 2 .
- Refer to INSTALLING RIGHT HIGH PRESSURE PUMP .
- Refer to INSTALLING THE LEFT HIGH PRESSURE PUMP .
- Refer to INSTALLING THE HEAT SHIELD OF THE CRANKCASE VENTILATION OF CYLINDERS 5 TO 8 .
- Refer to INSTALLING FUEL DELIVERY LINE .
- Refer to ATTACHING THE RIGHT FUEL SUPPLY LINE .
- Refer to SECURING COOLANT LINES FOR THE EXHAUST TURBOCHARGERS .
- Refer to INSTALLING RAIL ON BANK 2 .
- Refer to INSTALLING THE IGNITION COILS OF CYLINDER BANK 2 .
- Refer to INSTALLING THE IGNITION COILS OF CYLINDERS 1 AND 2
- Refer to FASTENING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND THE HEAT EXCHANGER .
- Refer to INSTALLING THE LEFT THROTTLE BODY .
- Refer to INSTALLING THE CHARGE AIR COOLER ON THE LEFT AND RIGHT .
- Refer to INSTALLING ALTERNATOR .
- Refer to INSTALL DRIVE BELT .
- Refer to INSTALLING THE RIGHT UNFILTERED-AIR DUCT .
- Refer to INSTALLING OIL FILLER NECK .
- Refer to INSTALLING LEFT AND RIGHT EXHAUST TURBOCHARGERS .
- Refer to INSTALLING UPPER CATALYTIC CONVERTER NEAR ENGINE FOR BANK 2. .
- Refer to INSTALLING CATALYTIC CONVERTER NEAR THE ENGINE ABOVE CYLINDER BANK 1 .
- Refer to INSTALLING HEAT SHIELD, TOP .
- Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
- Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
- Refer to INSTALLING THE CROSSING OF THE TRANSMISSION WIRING HARNESS .
- Refer to INSTALLING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE .
- Refer to INSTALLING BRACKET FOR RIGHT INTAKE SILENCER .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR FOR CYLINDERS 1 TO 4 .
- Refer to INSTALL RIGHT INTAKE SILENCER HOUSING .
- Refer to INSTALLING THE LEFT UNFILTERED-AIR DUCT .
- Refer to INSTALLING THE LEFT INTAKE SILENCER BRACKET .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR FOR CYLINDERS 5 TO 8 .
- Refer to INSTALL THE ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
- Refer to FASTENING THE ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
- Refer to REMOVING THE ENGINE FROM THE ENGINE SUPPORT BRACKET .
- Refer to ATTACHING THE ENGINE TO THE LIFTING TABLE .