Installing Pistons - Cylinder Bank 4-6

Preliminary work: Crankshaft is inserted in crankcase half 4-6; pistons and connecting rods are pre-fitted (see  ASSEMBLY  ). 

1. Secure the crankshaft to the main bearing in the middle using holding bridge 9779 -1-  .
   1. 1.1. Tighten two fastening screws -2-  hand-tight.
      Fig 1: Identifying Holding Bridge 9779 For Crankshaft

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2. Tighten three external Torx screws (M8 x 1 x 25) -2-  used to secure the vibration damper to the crankshaft flange hand-tight.
   1. 2.1. Turn the crankshaft using turning device 9773 -1-  so that the con-rod journal is at bottom dead center position.
      Fig 2: Turning Crankshaft (Without Vibration Damper)

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      Information 

      • The parting surface between the connecting rod and connecting rod cap is broken during the manufacturing process. 
      • Assign connecting rod cap to the relevant connecting rod immediately after removal. 
      • Also check the four-digit matching number. 
      • Replace connecting rod bolts. 
      • Replace connecting rod bearings. 
3. Check that the new con-rod bearing shells are seated correctly (check locking lugs).
   Fig 3: Locating Locking Lugs For Connecting Rod Bearings

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   1. 3.1. Check allocation of connecting rod to connecting rod cap (matching number -1-  and data matrix code). These must be facing the exhaust manifold in installation position.
      Fig 4: Identifying Connecting Rod On Crankshaft

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4. Install piston and connecting rod.
   1. 4.1. For re-installation, fit the relevant piston into the related cylinder bore according to the inscription -4 to 6-  (cylinder 4 on belt side).
      Fig 5: Locating Marking And Installation Position Of Pistons 4-6

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   2. 4.2. Check installation position of pistons. The cone-shaped neck -1-  must be facing the intake side -E-  . The matching number and data matrix code on the connecting rod -2-  must be facing the exhaust side.
      Fig 6: Identifying Matching Number On Connecting Rod

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   3. 4.3. Align piston rings. Offset the ring gaps by 120°. Check the twist lock -arrow-  at the second ring groove.
      Fig 7: Locating Twist Lock On Second Piston Ring

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   4. 4.4. Coat piston and tools funnel 9784  (3.4-litre) or funnel 9784/3  (2.9-litre) with new engine oil.
   5. 4.5. Slide the piston -1-  as far as required into the assembly funnel -2-  until the lower edge of the piston is flush with the surface of the tool.
      Fig 8: Sliding Lower Edge Of Piston Flush With Surface Of Assembly Funnel

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   6. 4.6. Guide connecting rod and piston -1-  into the cylinder bore and place assembly funnel -2-  on the crankcase.
      Fig 9: Inserting Piston Into Cylinder Bore

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   7. 4.7. Press the piston into the cylinder bore immediately and hold the assembly funnel -1-  firmly while doing this. The wooden or plastic handle of a hammer -2-  can be used to do this.
      Fig 10: Pressing Piston Into Cylinder Bore

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   8. 4.8. Remove assembly funnel.
   9. 4.9. Fit the correct connecting rod cap with new screws.
   10. 4.10. Repeat these steps for pistons 5 and 6.
5. Pre-fit connecting rods 1-3 with new bearings and the relevant connecting rod caps and new screws -2-  on the crankshaft.
   Fig 11: Identifying Connecting Rod Cap On Cylinder Bank 1-3

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   1. 5.1. The matching number -1-  and data matrix code are facing the exhaust side.
      Fig 12: Identifying Connecting Rod Matching Number

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6. Tighten all connecting rod caps -2-  according to specifications.

   → Initial tightening: 20 Nm (15 ftlb.) 

   → Final tightening - torque angle: 80° 

   Fig 13: Identifying Connecting Rod Cap Screws

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7. Fit rubber sleeves on connecting rods 1-3 to protect the cylinder lining (assembly aid 9795  ).