Pre-Assembly Of Pistons And Connecting Rods

Information 

• Ensure even weight distribution when installing new pistons or connecting rods. 
• Only one weight group is permitted per engine. 

Component overview 

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Connecting rod/piston

1. Connecting rod bolts, M10 x 1.25 x 51

Tools: 

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Tool 9778

1. > 9778 - Retaining device 
2. Inserts that can be used for the relevant pistons: 9778 

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. 

1. Allocate connecting-rod bearings based on the marking on the crankshaft.
   1. 1.1 Read off the bearing shell color from the series of letters. The con-rod marking -3-  indicates the con-rod journal. Fit in the specified sequence -3, 1, 4, 2-  .

      The color assignment -4-  is shown above the relevant connecting rod number!

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      Marking for bearing shell allocation on the crankshaft

      1. B  Blue bearing shells ("thick")
      2. G  Yellow bearing shells ("medium")
      3. R  Red bearing shells ("thin")
      4. Main bearing designation: SL = support bearing (1), HL = main bearing (2-5), sequence 1-5, starting at the belt side 
      5. Color assignment
      6. PL = connecting-rod bearing, sequence according to cylinder (3 -1- 4-2) 
      7. Color assignment
   2. 1.2 Fit new con-rod bearing shells in the connecting rod cap and connecting rod and grease with Optimol Optipit grease (Part No. 000.043.204.17).
   3. 1.3 Check that the new con-rod bearing shells are seated correctly (check retaining lugs) -arrow-  .

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      Retaining lugs for connecting rod bearings

   4. 1.4 Secure connecting rod cap with relevant connecting rod and new screws by hand.
2. Fit pistons and connecting rods for cylinders 3-4 (the positions of the above-mentioned markings also apply for the pistons and connecting rods for cylinders 1-2).
   1. 2.1 The matching number -2-  and data matrix code -inset-  on the correctly installed connecting rod must be facing the exhaust side! 
   2. 2.2 Marking points on connecting rod and connecting rod cap must be on the same side.
   3. 2.3 In contrast, the data matrix code -1-  on the piston must be facing the intake side! 
   4. 2.4 The pistons for cylinders 1-2 are pre-fitted without connecting rods.

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   Matching number on connecting rod

3. Insert connecting rod with piston -1-  or only the piston into the > 9778 - retaining device  .
   1. 3.1 Use a suitable piston receiving element.

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   Piston/connecting rod in retaining device 9778

   WARNING: Preloaded or pressurized components 

   • Risk of eye injuries 
   • Risk of bruising 
     • → Wear personal protective gear.
     • → Secure components to prevent them from falling off suddenly.
4. First, fit the piston-pin circlip, which must be facing the flywheel side later.
   1. 4.1 Fit the circlip on the side of the piston that does not have an assembly groove for the assembly tool.
   2. 4.2 Fit circlip for piston 1 -1-  facing the flywheel side and circlip for piston 2 facing the belt side. Use a small screwdriver to do this.
   3. 4.3 Press the circlip in with your thumbs and guide it to its final position with the screwdriver.

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   View of circlip facing flywheel side - hook at 12 o'clock position (engine vertical)

   Pistons and connecting rods for cylinders 3-4: 

5. Same procedure as for the circlips for pistons 1 and 2, i.e. fit the circlips inside the engine. Use the relevant assembly tool (9776, 9776/2 or 9776/3) for installation.
   1. 5.1 Coat piston pin with new engine oil and press it into the relevant piston/connecting rod assembly.
   2. 5.2 Turn the groove for the small hook on the tool -2-  towards the observer.

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      Example of pressing piston-pin circlip into tool 9776

   3. 5.3 Slide a new circlip -1-  into the assembly tool and press the edges together.
   4. 5.4 Position small hook facing the groove -arrow-  .

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      Small hook facing groove

   5. 5.5 Turn the circlip -1-  as required.

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      Turning piston-pin circlip in tool

   6. 5.6 Pull back and hold push rod in tool. Place the pipe -1-  on a hard surface. Slowly guide the push rod down and press the circlip into installation position. You should hear a distinct click.

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   Pressing circlip into assembly position

6. >9776 - Assembly tool  must be positioned on the piston in such a way that the small hook is lying in the half-moon-shaped bore -arrow-  .

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   Tool 9776 at assembly groove on piston

   View of piston 3 on the circlip -1-  in the tool.

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   Circlip position viewed from the piston (towards belt side)

   1. 6.1 Hold on firmly to the tube of the tool -1-  and tap the push rod slightly towards the piston with the ball of your hand -arrow-  . The circlip will lock with a clearly audible click.

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   Fitting circlip on piston in retaining device

7. Remove piston and connecting rod from the > 9778 - retaining device  .
8. If piston rings will be replaced on the re-installed pistons, these can be removed and fitted by hand.
   IMPORTANT: Check installation position and avoid breakage!