Pre-Assembly Of Pistons And Connecting Rods

Information 

• Assign connecting rod cap to the relevant connecting rod immediately after removal. 
• Check four-digit matching number. 
• Replace connecting rod bolts. 
• Replace connecting rod bearings. 

Information 

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

Information 

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Marking for bearing shell allocation on the crankshaft

• PL marking indicates the bearing shell allocation for the con-rod journal. 
• Read off from left to right. 
• Fit bearings according to numbering sequence. 

1. Allocate connecting-rod bearings based on the marking on the crankshaft.

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   Retaining lugs for connecting rod bearings

   1. 1.1  Read off bearing shell colour from the series of letters -1-  .
   2. 1.2  Insert new con-rod bearing shells in the connecting rod cap and connecting rod and grease with Optimal (Part No. 000.043.204.17).
   3. 1.3  Check that the locking lugs -arrow-  are seated correctly.
   4. 1.4  Secure connecting rod cap with relevant connecting rod and new screws by hand.

   Information 

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   Markings on connecting rods and pistons

   • The matching number -2- and data matrix code -inset- on the correctly installed connecting rod must be facing the exhaust side. 
   • The cone-shaped neck and data matrix code -1- on the piston must be facing the intake side. 
   • The positions of the listed markings also apply to pistons and connecting rods on cylinders 1 to 3. 
   • The pistons for cylinders 1 to 3 are pre-assembled without connecting rods. 
2. Fit pistons and connecting rods for cylinders 4 - 6.
3. Insert connecting rod -1-  with piston or only the piston into the > 9778 - retaining device-2-  .

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   Piston/connecting rod in retaining device

4. Pull off piston receiving element and fit > 9778/1 - piston receiving element  .
   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.

5. Install piston-pin circlip -1-  towards the flywheel side using > 9776 - assembly tool  . The hook on the retaining ring must be at 12 o'clock position (when the engine is vertical).

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   Circlip on the flywheel side

6. Turn piston and connecting rod by 180° and install circlip -1-  towards the belt side using > 9776 - assembly tool  .
   1. 6.1  Coat piston pin with new engine oil and press it into the relevant piston/connecting rod assembly.
   2. 6.2  Turn the groove for the small hook on the tool -2-  towards the observer.

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      Piston-pin circlip in assembly tool

   3. 6.3  Press the edges together and push the new circlip -1-  into > 9776 - the assembly tool  .
   4. 6.4  Turn the small hook towards the groove -arrow-  .

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      Small hook facing groove

   5. 6.5  Turn the circlip -1-  as required.

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      Piston-pin circlip in tool

   6. 6.6  Pull back and hold push rod in tool. Place the pipe -1-  on a hard surface.
   7. 6.7  Slowly guide the push rod down and press the circlip into installation position until you hear a distinct noise.

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   Circlip in assembly position

   Information 

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   Circlip position viewed from the piston (towards belt side)

   • View of piston on circlip -1- in assembly tool. 
7. > 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

   1. 7.1  Tap the push rod of the assembly tool -1-  lightly towards the piston with the ball of your hand -arrow-  until the circlip engages.

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      Circlip on piston

   2. 7.2  Check the position of the hook -2-  on the circlip -1-  . The hook -2-  must be at about 9 o'clock position.

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   Retaining ring on piston (view on belt side)

8. Remove piston and connecting rod from > 9778 - retaining device  .