Fitting pistons and piston rods in the crankcase half or bearing housing of cylinder bank 1 - 3: Installation

1. Fasten crankcase half, cylinders 1 - 3, in conjunction with mounting elements 9590 to engine holder 9589.
   Fig 1: Fastening Crankcase Half To Engine Holder - Cylinders 1-3

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2. Clean bearing housing support surface, particularly in area of oil duct. Check dowel sleeves for correct seating.
   Fig 2: Checking Dowel Sleeves For Correct Seating - Cylinders 1-3

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3. Installation of the complete bearing housing in the crankcase half, cylinders 1-3. As the bearing housing is heavy, it should be installed using a workshop crane.

   Carefully and in stages, lower bearing housing with fitted holder 9607 and using a workshop crane towards the dowel sleeves (2 ea.), observing the following points:

   Fig 3: Lifting Bearing Housing Using Workshop Crane Towards Dowel Sleeves

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   Fig 4: Inspecting Lower Bearing Housing

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   1. To aid in guiding, screw two cylinder head screws approx. 3 turns into the bearing housing from below.
      Fig 5: Identifying Cylinder Head Screws

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   2. Just before reaching the final installation position, pull the loosened intermediate-shaft flange out of the housing area and rotate the flange so that the two flange lugs that are spaced closest together face upwards.
      Fig 6: Pulling Loosened Intermediate-Shaft Flange Out Of Housing Area

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      Fig 7: Aligning Intermediate-Shaft Flange So That Two Flange Lugs That Are Spaced Closest Together Face Upwards

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   3. After lowering, check whether there is sag in the upper chain area or sufficient lever travel exists. Lift the bearing housing and check the chain installation if necessary.
      Fig 8: Checking Whether There Is Sag In The Upper Chain Area Or Sufficient Lever Travel Exists

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   4. Remove two cylinder head screws (guidance aid).
4. For the following assembly procedure - piston installation, cylinders 1, 2 and 3 - the crankcase half and bearing housing unit must be held by at least two screw connections. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below. Tightening torque 30 Nm (22 ftlb.). Use Torx screwdriver insert T50 or T55.
   Fig 9: Identifying Plastic Spacer Sleeves (Special Tool 9613)

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5. Turn crankcase by 180° on the assembly support. Cylinders 1, 2 and 3 face upwards.
6. Fit belt pulley. Screw in fastening screw by hand.
7. Turn crankshaft clockwise until the bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
   Fig 10: Aligning Bore U4 With Fixing Bore On The Belt Pulley With The Fixing Bore On The Crankcase

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8. Remove preassembled connecting rod with piston of cylinder 1 from the assembly fixture.
   Fig 11: Removing Preassembled Connecting Rod With Piston Of Cylinder 1 From Assembly Fixture

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9. Align the gaps of the upper piston rings offset by 180°. Make sure that the gap of the second piston ring is aligned with the twist lock.
   Fig 12: Ensuring Gap Of The Second Piston Ring Is Aligned With The Twist Lock

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10. Place piston with connecting rod in installation position.
    Fig 13: Placing Piston With Connecting Rod In Installation Position

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11. Tighten piston ring restraining strap and fit piston with connecting rod.
    NOTE: Generously coat the piston and restraining strap with engine oil before fitting the piston.
    Fig 14: Identifying Piston And Restraining Strap

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12. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves.
    Fig 15: Tapping Piston Into Cylinder

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    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.
13. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9598). Use assembly aid with larger diameter and insertion depth.
    Fig 16: Pushing Piston Down With Assembly Aid

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14. Turn crankcase by 180°. Make sure the bearing shell is correctly seated in the connecting rod. The fixing lugs point to the oil pan.
    Fig 17: Ensuring Bearing Shell Is Correctly Seated In Connecting Rod

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15. Fit end caps. Lubricate bearing shells. The recesses of the connecting-rod bearing twist lock must face each other.
    Fig 18: Identifying Connecting-Rod Bearing Twist Lock Recesses

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    Fig 19: Fitting Connecting Rod End Caps

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16. Tightening specification:

    Oil thread and contact surface.

    1. Initial tightening 20 Nm (15 ftlb.) 

       To facilitate subsequent checks it is recommended that the screw heads be marked with a colored pen after initial tightening.

    2. Final tightening 1 x 90° turn 

    Use 10 mm socket wrench insert (double hexagon).

17. Fitting piston and connecting rod in cylinder 2

    Turn crankcase by 180°. Turn crankshaft clockwise until the bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.

    Fig 20: Aligning Bore U5 On The Belt Pulley With Fixing Bore On Crankcase

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18. Prepare preassembled connecting rod with piston of cylinder 2 for installation. Perform the following assembly steps as described from Step 8 to Step 16.
19. Fitting piston and connecting rod in cylinder 3 Rotate crankshaft clockwise until bore U6 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
    Fig 21: Aligning Bore U6 On The Belt Pulley With Fixing Bore On Crankcase

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20. Prepare preassembled connecting rod with piston of cylinder 3 for installation. Perform the following assembly steps as described from Step 8 to Step 16.
    NOTE: Leave crankshaft at position U6 after fitting the piston and connecting rod in cylinder 3. This position is necessary for subsequent fitting of the piston of cylinder 6.
21. Remove belt pulley.

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 On Oil Guide

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   Fig 2: Identifying Two Seals, Left And Right Of 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: Turning Star Knob Clockwise Until Centring Mandrel Is Braced In Crankcase Half

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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. Instructions: see SEALING OF CRANKCASE HALVES .
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 (9.5 ftlb.). Tightening sequence, see TIGHTENING SEQUENCE FOR CRANKCASE HALVES . Immediately remove silicone material emerging in the area of the oil pan sealing surface.
   Fig 4: Removing Silicone Material Emerging In Area Of Oil Pan Sealing Surface

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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: Turning Star Knob Anti-Clockwise

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

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

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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 Fixing Bore On Crankcase

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

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13. Fasten centering aid, special tool 9602/3, with two countersunk screws with crosshead (M6 x 20) on the crankcase.
    Fig 10: Identifying Special Tool 9602/3

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    NOTE: Centring aid, special tool 9602/2, is used as from engine numbers 66X07679 and 68X03514.
    Fig 11: Identifying 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 12: Inserting Centering Mandrel In The Assembly Bore

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    Fig 13: Aligning Connecting Rods In 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.
    1. Check whether the piston pin circlip is present and was fitted correctly (flywheel side).
       Fig 14: Checking Whether Piston Pin Circlip Is Present And Was Fitted Correctly

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    2. Before installation, check whether the assembly tube (2) can be moved easily in the piston eye; remove burr if necessary.
       Fig 15: Identifying Assembly Tube

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       Fig 16: Checking Whether The Assembly Tube Can Be Moved Easily In The Piston Eye

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16. Move piston to installation position, position the piston ring restraining strap and insert the piston.
    Fig 17: Moving Piston To Installation Position

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    Fig 18: Identifying Position Piston Ring Restraining Strap

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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 Down Piston

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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 Again Using Centring 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 Using Special Tool 9602

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    Fig 22: Aligning Piston And Connecting Rod Again Using Centring 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: Identifying Special Tool 9603/1

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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 Tube

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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

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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 Into Crankcase Assembly Bore With Circlip Fitted

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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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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 29: 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 30: Identifying Shop-Made Electric Torch With Mirror

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    Fig 31: Visually Inspecting Correct Seating Of The Piston Pin Circlip

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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 32: Aligning Bore U5 On The Belt Pulley With Fixing Bore On Crankcase

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28. Perform the following assembly steps for piston installation in cylinder 5 as described from Step 14 to Step 26. A spacer sleeve (3) is additionally required when fitting the piston pin circlip in the piston of cylinder 5.
    Fig 33: Identifying Assembly Tool For Piston Installation In Cylinder 5

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    Fig 34: Fitting The Piston Pin Circlip In 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 35: Aligning Bore U4 On The Belt Pulley With Fixing Bore On Crankcase

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30. Perform the following assembly steps for piston installation in cylinder 4 as described from Step 14 to Step 26.
31. Two spacer sleeves (3 (+) 4) are additionally required when fitting the piston pin circlip in the piston of cylinder 4.
    Fig 36: Identifying Spacer Sleeves

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    Fig 37: Fitting Piston Pin Circlip In Piston Of Cylinder 4

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32. Remove centering aid 9602/3.
    Fig 38: Identifying Centring Aid 9602/3

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33. Visually inspect correct seating of the piston pin circlip on the piston of cylinder 4.
    Fig 39: Inspecting Correct Seating Of Piston Pin Circlip On Piston 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 center of piston crown. Coat suitable plastic mandrel with instant adhesive. Allow the adhesive to cure. Pull out piston. Remove plastic mandrel immediately.
    Fig 40: Removing 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 ftlb.).
    Fig 41: Identifying 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.

    View from the belt pulley side 

    Fig 42: Identifying Guide Rail & Tensioning Rail Of Cylinder Bank 1-3

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    View from the flywheel side 

    Fig 43: Identifying Guide Rail & Tensioning Rail Of Cylinder Bank 1-3 (View From The Flywheel Side)

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36. Fit guide rails and tensioning rails of cylinder bank 4 - 6 (flywheel side); fit guide rails in correct position.

    View from the belt pulley side 

    Fig 44: Identifying Guide Rail & Tensioning Rail Of Cylinder Bank 4-6

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    View from the belt pulley side 

    Fig 45: Identifying Guide Rail & Tensioning Rail Of Cylinder Bank 4-6 (View From The Belt Pulley Side)

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37. Fit oil pump with coolant guide housing. For assembly instructions, refer to REMOVING AND INSTALLING OIL PUMP WITH COOLANT GUIDE HOUSING .
    Fig 46: 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 ftlb.).

    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 ftlb.).

    Fig 47: Tightening Lock Nut And Holding With Slotted Screwdriver

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39. Fit belt pulley.

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

Tightening torque 50 Nm (37 ftlb.)

Fig 48: Tightening Belt Pulley Hexagon-Head Bolt Using Socket Wrench

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Fig 49: Identifying Hexagon-Head Bolt Tightening Angle

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Tightening sequence: