Fitting Pistons On Cylinder Bank 4 - 6

1. Thoroughly clean sealing surface of the crankcase half of cylinder bank 1-3.
2. Ensure that the profile seals on the oil guide and the two seals left and right of the coolant duct are seated correctly.
   Fig 1: Identifying Profile Seals

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   Fig 2: Locating Two Seals On Left And Right Of The Coolant Duct

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3. Place centering mandrel, special tool 9645, on the take-up bore of the oil pump and turn the star knob clockwise until the centering mandrel is braced in the crankcase half (oil pressure builds up in centering mandrel).
   Fig 3: Installing Centering Mandrel (9645) On The Take-Up Bore Of The Oil Pump

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4. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4-6.
5. Before fitting the crankcase half, have a second person pull the drive chain out of the chain space using a wire.
6. Carefully set the crankcase half in place so that the sealing bead is not damaged.
7. Fasten crankcase half. Tightening torque 13 Nm (10.0 ft.lb). Refer to DISASSEMBLING AND ASSEMBLING CRANKCASE HALVES, ENGINE M96/20, M96/21, M96/22 . Immediately remove silicone material emerging in the area of the oil pan sealing surface.
   Fig 4: Locating Oil Pan Sealing Surfaces

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8. Relieve centering mandrel. Turn star knob anti-clockwise (oil pressure drops) and remove centering mandrel. Remove silicone residue.
   Fig 5: Relieving Centering Mandrel

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9. Fasten engine holder, special tool 9589, to the crankcase half of cylinder 4-6 (3rd fastening point).
   Fig 6: Identifying Special Tool (9589) To The Crankcase Half Of Cylinder 4-6

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10. Remove plastic spacer sleeves, special tool 9613.
    Fig 7: Removing Plastic Spacer Sleeves 9613

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11. Fit belt pulley. Screw in fastening screw by hand. Cylinder bank 4-6 faces upward. Bore U6 on the belt pulley must be aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
    NOTE: Fixing of the belt pulley is absolutely necessary in order to ensure precise fitting of the pistons.
    Fig 8: Aligning Bore U6 On The Belt Pulley With The Fixing Bore On The Crankcase

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12. Unscrew plug for piston pin assembly bore. Use a 12 mm hexagon socket wrench insert.
    Fig 9: Unscrewing Plug For Piston Pin Assembly Bore

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13. Fasten centering aid, special tool 9602/2, with two countersunk screws with crosshead (M6 x 20) on the crankcase.
    Fig 10: Fastening Centering Aid With Special Tool (9602/2)

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14. Align connecting rod of cylinder 6. Insert centering mandrel, special tool 9608, in the assembly bore.
    Fig 11: Inserting Centering Mandrel With Special Tool (9608) In The Assembly Bore

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    Fig 12: Inserting Centering Mandrel

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    NOTE:

    • The centering mandrel remains in the eye of the connecting rod until the piston contacts the centering mandrel during fitting.
15. Install piston of cylinder 6.

    Check whether the piston pin circlip is present and was fitted correctly (flywheel side).

    Fig 13: Checking Piston Pin Circlip Installed Position

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    Before installation, check whether the assembly tube (2) can be moved easily in the piston eye; remove burr if necessary.

    Fig 14: Identifying Assembly Tube

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    Fig 15: Installing Assembly Tube In Piston

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16. Align the gaps of the piston rings offset by 120°. Position piston ring clamp and fit piston.
    Fig 16: Identifying Piston Ring Compressor

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    Fig 17: Identifying Piston Installed Position

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    Piston in installation position

    Fig 18: Compressing Piston Rings

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    NOTE:

    • Generously coat the piston, cylinder and restraining strap with engine oil before fitting the piston.
17. Use the handle of a hammer to tap the piston gently into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves.
    NOTE:

    • The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
18. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9698) to the centering mandrel stop.
    Fig 19: Pushing Piston Down With The Assembly Aid (Special Tool 9698)

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19. Carefully withdraw the centering mandrel and push the piston down to the stop.
20. Align piston and connecting rod again using the centering mandrel.
    Fig 20: Aligning Piston And Connecting Rod Using The Centering Mandrel

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21. Push in piston pin as far as it will go into the piston using the pressure pin of special tool 9602.
    Fig 21: Pushing In Piston Pin Into The Piston Using Pressure Pin Of Special Tool 9602

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    Fig 22: Aligning Piston And Connecting Rod Using The Centering Mandrel

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22. Prepare piston pin circlip for fitting on the piston. It is important to pre-fit the circlip on a firm surface. The circlip must be pre-fitted only immediately prior to fitting on the piston pin eye.
    1. Manually insert the new circlip into the conical part of the assembly sleeve, special tool 9603/1.
       Fig 23: Inserting New Circlip Into The Conical Part Of The Assembly Sleeve

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    2. Place assembly sleeve 9603/1 onto the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical sleeve into the assembly tube.
       Fig 24: Identifying Assembly Sleeve (9603/1)

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       Fig 25: Sliding Circlip From Conical Sleeve Into Assembly Tube

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    3. Remove assembly sleeve 9603/1 and visually inspect the correct position of the circlip in the assembly tube.
    CAUTION: Danger of injury if circlip springs out!

    Check position of the circlip only by visual inspection of the assembly tube from the side.

    Fig 26: Checking Position Of Circlip By Visual Inspection Of The Assembly Tube From The Side

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23. Push assembly tube through the centering piece into the crankcase assembly bore with the circlip fitted.
    Fig 27: Pushing Assembly Tube Through Centering Piece

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24. Carefully and gently insert the pressure pin until it contacts the piston pin circlip.
    Fig 28: Inserting Pressure Pin Until It Contacts Piston Pin Circlip

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    NOTE:

    • When inserting the pressure pin, the plastic ring on the pressure pin may touch the belt pulley. Either rework the plastic ring or remove the belt pulley briefly.
    Fig 29: Plastic Ring On The Pressure Pin May Touch The Belt Pulley

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25. Move the piston pin circlip to its installation position by briefly and forcefully striking the palm of your hand against the star knob of the pressure pin.
    Fig 30: Moving Piston Pin Circlip To Its Installation Position

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26. Visually inspect correct seating of the piston pin circlip, for example, with a shop-made electric torch with mirror.
    Fig 31: Identifying Electric Torch With Mirror

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    Fig 32: Visually Inspecting Correct Seating Of The Piston Pin Circlip

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    Drawing shows a torch with adjustable mirror

27. Fitting piston in cylinder 5. Advance the crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
    Fig 33: Aligning Bore U5 On The Belt Pulley With The Fixing Bore On The Crankcase

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28. Perform the following assembly steps for piston installation in cylinder 5 as described from Steps  14 to  26. A spacer sleeve (3) is additionally required when fitting the piston pin circlip in the piston of cylinder 5.
    Fig 34: Identifying Spacer Sleeve

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    Fig 35: Installing Piston Pin Circlip In The Piston Of Cylinder 5

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29. Fitting piston in cylinder 4. Advance the crankshaft clockwise until bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
    Fig 36: Aligning Bore U4 On The Belt Pulley With The Fixing Bore On The Crankcase

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30. Perform the following assembly steps for piston installation in cylinder 4 as described from Steps  14.
31. Two spacer sleeves (3 + 4) are additionally required when fitting the piston pin circlip in the piston of cylinder 4.
    Fig 37: Identifying Spacer Sleeve

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    Fig 38: Fitting Piston Pin Circlip In Piston Of Cylinder 4

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32. Remove centering aid 9602/2.
    Fig 39: Removing Centering Aid 9602/2

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33. Visually inspect correct seating of the piston pin circlip on the piston of cylinder 4.
    Fig 40: Inspecting Correct Seating Of Piston Pin Circlip Of Cylinder 4

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    NOTE: If the piston, piston pin or piston pin circlip are incorrectly assembled, the corresponding piston can be pulled out of the cylinder as follows. Degrease Centre of piston crown. Coat suitable plastic mandrel with instant adhesive. Allow the adhesive to cure. Pull out piston. Remove plastic mandrel immediately.
    Fig 41: Removing Piston Using Plastic Mandrel

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34. After fitting the pistons, fit a screw plug and new sealing ring in the assembly bore. Use a 12 mm hexagon socket wrench insert. Tightening torque 80 Nm (59 ft.lb).
    Fig 42: Fitting Screw Plug In The Assembly Bore

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35. Fit guide rail and tensioning rail of cylinder bank 1-3 (flywheel side); fit guide rails in correct position.
    Fig 43: Exploded View Of Guide Rail And Tensioning Rail Of Cylinder Bank 1-3

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    View from the belt pulley side

    Fig 44: View Of Guide Rail And Tensioning Rail Of Cylinder Bank 1-3 - From Belt Pulley Side

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    View from the flywheel side

36. Fit guide rails and tensioning rails of cylinder bank 4-6 (flywheel side); fit guide rails in correct position.
    Fig 45: Exploded View Of Guide Rail And Tensioning Rail Of Cylinder Bank 4-6

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    View from the belt pulley side

    Fig 46: View Of Guide Rail And Tensioning Rail Of Cylinder Bank 4-6 - From Belt Pulley Side

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    View from the belt pulley side

37. Fit oil pump with coolant guide housing Assembly instructions: refer to REMOVING AND INSTALLING OIL PUMP WITH COOLANT GUIDE HOUSING .
    Fig 47: Fitting Oil Pump With Coolant Guide Housing Assembly

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38. Fit intermediate-shaft flange.

    Grease sealing ring in area of intermediate-shaft flange.

    Grease take-up bore in area of the crankcase. Carefully press in the intermediate flange.

    Screw in new micro-encapsulated hexagon-head bolts M6 x 20 (3 ea.).

    Tightening torque 10 Nm (7.5 ft.lb).

    Tighten lock nut with the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.9 x 1.1 at the slotted threaded pin.

    Tightening torque 11 Nm (8.0 ft.lb).

    Fig 48: Tightening Intermediate-Shaft Flange Lock Nut With Socket Wrench

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39. Fit belt pulley.
    NOTE:

    • Check whether there are foreign objects in the drive belt grooves of the belt pulley and remove them if necessary.

Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.

Tightening torque 50 Nm (37 ft.lb)

Fig 49: Tightening Belt Pulley Hexagon-Head Bolt

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Final tightening: 1 x 90° turn

Fig 50: Angle Tightening For Bolt

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