Installing Pistons - Cylinder Bank 1-3

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1. Assemble the crankcase.

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2. Secure the vibration damper to the crankshaft flange with two external Torx screws (M8 x 1 x 25).
3. Turn con-rod journal for cylinder 3 to installation position.
   1. 3.1. To do this, use turning device 9773  to turn the crankshaft to the bottom dead center position U 3/6  at the vibration damper.
      Fig 1: Turning Crankshaft To Bottom Dead Centre Position U 3/6 At Vibration Damper

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4. Pull off the boot on the connecting rod -1-  , set it in a vertical position and secure in place with a centering mandrel 9782  (diameter: 22 mm) -2-  .
   Fig 2: Guiding Centering Mandrel Into Assembly Bore

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   View through cylinder bore: connecting rod eye -1-  and centering mandrel -2-  .

   Fig 3: Centering Connecting Rod Using Tool 9782 (Diameter 22)

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5. Install pistons for cylinders 1-3.
   1. 5.1. Insert displacement bodies -1-  .
   2. 5.2. For re-installation, fit the relevant piston into the related cylinder bore according to the inscription -1 to 3-  (cylinder 3 on flywheel side).
      Fig 4: Identifying Marking Pistons

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   3. 5.3. Check installation position of pistons. The cone-shaped neck  and data matrix code on the piston -1-  must be facing the intake side, while the matching number -2-  and data matrix code on the connecting rod must be facing the exhaust side.
      Fig 5: Identifying Matching Number On Connecting Rod

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   4. 5.4. Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow-  at the second ring groove.
      Fig 6: Locating Piston Ring Groove

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   5. 5.5. Coat piston and tools funnel 9784  (3.4-litre) or funnel 9784/3  (2.9-litre) with new engine oil.
   6. 5.6. Insert the piston into the assembly sleeve -1-  until the lower edge of the piston is flush with the surface of the sleeve -arrow-  .
      Fig 7: Inserting Piston Into Assembly Sleeve

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   7. 5.7. Guide the piston -1-  into the cylinder bore and carefully position the funnel -2-  on the crankcase.
      Fig 8: Inserting Piston Into Cylinder Bore

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   8. 5.8. Press the piston into the cylinder bore immediately and hold the assembly funnel -1-  firmly while doing this. The wooden handle of a hammer -2-  can be used to do this.
      Fig 9: Pressing Piston Into Cylinder Bore

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   9. 5.9. Remove assembly funnel.
6. Position piston in order to fit piston pin and circlip.
   1. 6.1. Tools for 3.4-litre pistons: Piston assembly aid 9787  with spacer ring 9787/3  and handle of assembly aid 9598  .
   2. 6.2. Tools for 2.9-litre pistons: Piston assembly aid 9787/2  and handle of assembly aid 9598  .
   3. 6.3. Use the relevant tool -1-  to press the piston into the cylinder bore as far as the contact surface of the centering mandrel 9782 -2-  .
      Fig 10: Pressing In Piston Using Assembly Aid 9787

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   4. 6.4. Pull out the centering mandrel -2-  and press the piston down at the same time until the assembly aid -1-  is positioned correctly.
7. Fix piston and connecting rod in place using a centering mandrel 9782  .
   Fig 11: Centering Piston And Connecting Rod

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8. Fit the piston pin.
   1. 8.1. Coat the piston pin with new engine oil and slide it onto the disassembly tool 9777  .
   2. 8.2. Secure the tool at the front hexagon -1-  and turn it anti-clockwise as far as it will go at the rear hexagon -2-  .
      Fig 12: Sliding Tool 9777 Into Piston Pin

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   3. 8.3. Slide the piston pin -1-  into the piston/connecting rod eye. Use the tool -2-  to guide the pin past the edge of the cylinder to the piston -arrow-  .
      Fig 13: Locating Piston Pin

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   4. 8.4. Tap the tool lightly with the ball of your hand, if necessary, while holding the tool firmly in place -1-  . Insert pin as far as it will go (touching the circlip).
      Fig 14: Tapping In Piston Pin Using Tool

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   5. 8.5. Turn the tool at the rear hexagon -2- in clockwise direction  until it pulls easily out of the piston pin without resistance.
      Fig 15: Turning Tool At Rear Hexagon 2 In Clockwise

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      Information 

      • Always replace piston-pin circlips following removal. 
9. Insert new piston-pin circlip into assembly tool 9776  .
   1. 9.1. The large hook -1-  on the circlip will have to be at 9 o'clock  position later (when engine is vertical).
      Fig 16: Inserting Piston-Pin Circlip Into Assembly Tool 9776

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   2. 9.2. Turn the groove for the small hook on the tool -1-  towards the observer.
      Fig 17: Pressing Piston-Pin Circlip Into Tool 9776

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   3. 9.3. Slide a new circlip -2-  into the assembly tool and press the edges together.
   4. 9.4. Position small hook facing the groove -arrow-  .
      Fig 18: Locating Small Hook Facing Groove

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      Turn the circlip -2-  as required:

      Fig 19: Turning Piston-Pin Circlip In Tool

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   5. 9.5. Pull back and hold push bar in tool. Place the pipe -1-  on a hard surface. Slowly guide the push bar down and press the circlip into installation position. You should hear a distinct click.
      Fig 20: Pressing Circlip Into Installation Position

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10. Fit the piston-pin circlip on the piston.
    1. 10.1. Assembly tool 9776 -1-  must now be guided into the assembly bore.
       Fig 21: Guiding Tool 9776 Into Assembly Bore

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       Fig 22: Identifying Circlip And Assembly Bore

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    2. 10.2. Position the tool with the small hook -arrow-  at about 11 o'clock  position and place it in the assembly groove on the piston.
       Fig 23: Locating Small Hook At 11 O'Clock Position

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    3. 10.3. Carefully turn the tube of the tool to the left and right while pressing slightly against the piston at the same time. You should feel a certain amount of resistance in the half-moon-shaped bore on the piston at both sides.
       Fig 24: Turning Tube Of Tool 9776

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    4. 10.4. Press the tube of the tool against the piston and hold it firmly in place. Then, tap the push bar slightly towards the piston with the ball of your hand. The circlip will lock with a clearly audible click.
    5. 10.5. Assembly tool 9776  must now be removed.
    6. 10.6. Check that the piston-pin circlip is seated correctly over cylinder bore 2 using a mirror -1-  and a torch. The correct assembly position is clearly visible -2-  .
       Fig 25: Checking Position Of Piston-Pin Circlip Using Mirror

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11. Turn con-rod journal for cylinder 2 to installation position.
    1. 11.1. To do this, use turning device 9773  to turn the crankshaft to the bottom dead center position U 2/5  at the vibration damper.
       Fig 26: Turning Crankshaft To Bottom Dead Centre Position U 2/5 At Vibration Damper

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    2. 11.2. Repeat steps  3- 10 for cylinder 2. Check the position of the circlip over cylinder bore 1.
12. Turn con-rod journal for cylinder 1 to installation position.
    1. 12.1. To do this, use turning device 9773  to turn the crankshaft to the bottom dead center position U 1/4  at the vibration damper.
       Fig 27: Turning Crankshaft To Bottom Dead Centre Position U 1/4 At Vibration Damper

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    2. 12.2. Repeat steps  3 - 10 for cylinder 1.
    3. 12.3. The position of the circlip can be checked on cylinder 1 through the assembly bore. The large hook -1-  must be at 9 o'clock position  when the engine is vertical.
       Fig 28: Identifying Installation Position Of Circlip In Piston

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13. Fit screw plug (M30 x 1.5) -1-  for fitting piston pin with a new sealing ring.
    Fig 29: Identifying Screw Plug For Removing/Fitting Piston Pins

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    1. 13.1. → Tightening torque: 80 Nm (59 ftlb.) 
14. Complete the engine.

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