Installing Pistons For Cylinders 4-6

Preliminary Work: Crankshaft Is Inserted In Crankcase Half 4-6; Pistons And Connecting Rods Are Pre-Fitted  .

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: Holding Bridge 9779 For Crankshaft

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2. Tighten three M8 screws -2-  securing the vibration damper to the crankshaft flange hand-tight.
   1. 2.1. Turn the crankshaft using Turning Device 9773  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 retaining lugs) -arrow-  .
   Fig 3: Locating Connecting Rod Bearings Retaining Lugs

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   1. 3.1. Check allocation of connecting rod to connecting rod cap (matching number -1-  and data matrix code).
      Fig 4: Identifying Connecting Rod Matching Number And Data Matrix Code Location

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      Information 

      • If pistons are to be replaced, only one weight group is permitted for all pistons  .
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. -E-  indicates the intake side.
      Fig 5: Locating Piston Marks

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

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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 pistons and tools with new engine oil.
   5. 4.5. Insert piston as far as required into the assembly funnel until the lower edge of the piston is flush with the surface of the tool.
      1. Piston
      2. Funnel 9784  (3.4-liter) or Funnel 9784/3  (2.7-liter)
      3. Piston-pin circlip
      Fig 8: Identifying Piston, Funnel 9784, Piston-Pin Circlip

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

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   7. 4.7. Press the piston into the cylinder bore immediately using the handle of a hammer -2-  and hold assembly funnel -1-  firmly while doing 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 on the crankshaft.
   1. 5.1. The matching number -1-  and data matrix code are facing the exhaust side.
      Fig 11: Identifying Connecting Rod Matching Number And Data Matrix Code Location

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6. Tighten all connecting rod caps according to specifications.
   Fig 12: 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  ).
8. Remove vibration damper in order to install the crankcase half.