Installing Pistons - Cylinders 1 To 3

Information 

• Replace piston-pin circlips following removal. 

Information 

• If pistons are to be replaced, only one weight group is permitted for all pistons. 

Information 

• Check guide and tensioning rails visually and for obvious signs of wear before installation and replace them if damaged. 
• Tensioning rails on cylinder bank 1 and 2 are identical. 
• Guide rails on cylinder bank 1 and 2 are identical. 
• The slots in the cylinder head must be positioned during installation. 

1. Turn the crankshaft.
   1. 1.1  Turn the crankshaft clockwise several times at the vibration damper using > 9773 - turning device  in order to check for smooth operation and correct function.
   2. 1.2  Turn the crankshaft using a > 9773 - turning device  until there are no pistons at the top dead center position.
2. Install new crankshaft sealing ring on the flywheel and belt side.

   > WM, 135955 REPLACING CRANKSHAFT SEALING RING - FLYWHEEL SIDE 

   > WM, 137455 REPLACING CRANKSHAFT SEALING RING - BELT SIDE 

3. Fit a vibration damper on the crankshaft flange and screw in screws as far as they will go by hand.
4. Turn con-rod journal for cylinder 3 to assembly position. To do this, use > 9773 - turning device  to turn the crankshaft to position -RHD vehicle -  bottom dead center -UT 3/6-  at the vibration damper.

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   Vibration damper

5. Pull off the boot, move connecting rod into a vertical position and fix in place using > 9782 - centering mandrel  .
   1. 5.1  Guide > 9782 - centering mandrel  with the correct diameter into the assembly bore.

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      Centering mandrel in assembly bore

   2. 5.2  Centre the connecting rod in the small connecting-rod eye -1-  using the > 9782 - centering mandrel-2-  .

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   Centering the connecting rod using tool 9782

   Information 

   • Data matrix code on the piston must be facing the intake side. 
6. Install pistons for cylinders -1 to 3-  .
   1. 6.1  Insert pistons -1 to 3-  into the relevant cylinder bore according to the marking, starting with piston -3-  .

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      Installation position of pistons

   2. 6.2  Align piston rings and re-position ring gaps by 120°. Check twist lock -Arrow-  at the second ring groove.

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      Twist lock on second piston ring

   3. 6.3  Check installation position of the pistons.
   4. 6.4  Coat pistons and tools with new engine oil.
   5. 6.5  Insert piston -1-  as far as required into the > 9784/2 - funnel-2-  until the lower edge of the piston is flush with the surface of the funnel.

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      Lower edge of piston flush with contact surface of funnel

      1	Piston
      2	> 9784/2 - Funnel
      3	Piston-pin circlip

   6. 6.6  Guide piston -1-  into the cylinder bore and carefully position the > 9784/2 - funnel-2-  on the crankcase - Arrow-  .

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      Piston in cylinder bore

   7. 6.7  Hold the > 9784/2 - funnel-1-  securely and press the piston into the cylinder bore -2-  using the handle of a hammer.

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      Piston

   8. 6.8  Remove > 9784/2 - funnel-1-  .
7. Position the piston.
   1. 7.1  Screw on > 9787 - piston assembly aid  with the handle of the > 9598 - assembly aid  .
   2. 7.2  Use the relevant assembly aid to press the piston into the cylinder bore as far as the contact surface of the > 9782 - centering mandrel-2-  .
   3. 7.3  Pull out > 9782 - centering mandrel-2-  and press the piston down at the same time until the assembly aid is positioned correctly.

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   Piston with assembly aid in the cylinder

8. Fix piston and connecting rod in place using > 9782 - centering mandrel  .

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   Piston with connecting rod

9. Fit piston pin.
   1. 9.1  Coat the piston pin with new engine oil and push it onto > 9777 - disassembly tool  .
   2. 9.2  Hold the tool securely at the front hexagonal handle -1-  and turn the rear hexagonal handle -2-  anti-clockwise -Arrow-  as far as it will go.

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      Piston pin on tool 9777

   3. 9.3  Push the piston pin as far as it will go into the piston/connecting-rod eye and guide the piston pin -1-  past as far as the piston using tool -2-  at the edge of the cylinder -Arrow-  .

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      Fitting piston pin

   4. 9.4  Tap the tool lightly with the ball of your hand if necessary, while holding the tool -1-  securely.

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      Tapping in piston pin using tool

   5. 9.5  Turn the tool clockwise at the rear hexagonal handle until it can be pulled out of the piston pin without resistance.

   Information 

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   Large circlip hook at 9 o'clock position (engine vertical)

   • The large hook -1- on the circlip will have to be at approx. 9 o'clock position later (when engine is vertical). 
10. Insert a new  piston-pin circlip -1-  into > 9776 - assembly tool  .
    1. 10.1  Turn the groove for the small hook on the tool -2-  towards the observer.

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       Piston-pin circlip in tool 9776

    2. 10.2  Press the edges together and push new circlip -1-  into > 9776 - assembly tool  .
    3. 10.3  Position small hook facing the groove -Arrow-  .

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       Small hook facing groove

    4. 10.4  Turn the circlip -1-  as required.

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       Circlip in tool

    5. 10.5  Pull back and hold push rod in tool. Place the pipe -1-  on a hard surface.

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       Circlip in assembly position

    6. 10.6  Slowly guide the push rod down and press the circlip into installation position -Arrow-  .

    Information 

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    Large circlip hook at 9 o'clock position (engine vertical)

    • The large hook -1- on the circlip will have to be at approx. 9 o'clock position later (when engine is vertical). 
11. Fit circlip -1-  on the piston.
    1. 11.1  Check the position of the circlip -1-  .

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       Circlip in tool

    2. 11.2  Guide > 9776 - assembly tool-1-  into the assembly bore -Arrow-  .

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       Tool 9776 in assembly bore

    3. 11.3  Position > 9776 - assembly tool-1-  with small hook at about 11 o'clock position -Arrow-  and place it in the assembly groove on the piston.

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       Small hook at 11 o'clock position

    4. 11.4  Carefully turn the pipe of the tool to the left and right -Arrows-  and press it slightly against the piston at the same time until a certain amount of resistance is felt in the half-moon-shaped bore on the piston at both sides.

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       Tube 9776

    5. 11.5  Press pipe of tool against the piston and hold securely.
    6. 11.6  Carefully tap the push rod slightly towards the piston with the ball of your hand until you hear a distinct noise.
    7. 11.7  Pull out > 9776 - assembly tool  .
    8. 11.8  Check that the piston-pin circlip -2-  is seated correctly over cylinder bore 2 using a mirror -1-  and pocket lamp.

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    Checking position of piston-pin circlip using a mirror

12. Turn con-rod journal for cylinder 2 to assembly position.
    1. 12.1  Use > 9773 - turning device  to turn the crankshaft to position -F-  bottom dead center -UT 2/5-  at the vibration damper.

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       Disconnecting vibration damper

    2. 12.2  Repeat steps See  to See  for cylinder 2.
13. Turn con-rod journal for cylinder 1 to assembly position.
    1. 13.1  Use > 9773 - turning device  to turn the crankshaft to position -D-  bottom dead center -UT 1/4-  at the vibration damper.

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       Vibration damper

    2. 13.2  Repeat steps See  to See  for cylinder 1.
    3. 13.3  The position of the circlip -1-  can be checked on cylinder 1 through the assembly bore.

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    Installation position of circlip in piston

14. Install screw plug -1-  .

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    Screw plug

    1. 14.1  Replace O-ring.
    2. 14.2  Screw in and tighten screw plug -1-  .

    > Tightening torque 80 N.m (59 ft lb.) 

15. Insert guide rail for cylinders 1 to 3, and screw in and tighten short bearing pin -1-  .

    > Tightening torque 10 N.m (7.5 ft lb.) 

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    Installing guide rails

16. Insert oil return (oil windage tray) -1-  and fit and tighten screws -2-  .

> Tightening torque 13 N.m (9.5 ft lb.) 

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Oil guide (oil windage tray)