Installing Pistons For Cylinders 1-3

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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.

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.

Turn the crankshaft.
Turn the crankshaft clockwise several times at the vibration damper using > 9773 - turning device in order to check for smooth operation and correct function.

Turn the crankshaft using a > 9773 - turning device until there are no pistons at the top dead centre position.
Install a new crankshaft sealing ring on the flywheel and belt side.
> Replacing crankshaft sealing ring - transmission side .

> Replacing crankshaft sealing ring (on belt side) .
Fit a vibration damper on the crankshaft flange and screw in screws as far as they will go by hand.
Turn con-rod journal for cylinder 3 to assembly position. To do this, use > 9773 - turning device to turn the crankshaft to position -B - bottom dead centre -UT 3/6- at the vibration damper.

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

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Centring mandrel in assembly bore

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

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Centring the connecting rod using tool 9782

Information
- Data matrix code on the piston must be facing the intake side.

Install pistons for cylinders -1 to 3- .

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

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

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Twist lock on second piston ring

Check installation position of pistons.

Coat pistons and tools with new engine oil.

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 sealing surface of funnel

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

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

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Piston in cylinder bore

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

> 9784/2 - Remove funnel-1- .

Position the piston.
> 9787 - Piston assembly aid must now be screwed to the handle of the > 9598 - assembly aid .

Use the relevant assembly aid to press the piston into the cylinder bore as far as the contact surface of the > 9782 - centring mandrel-2- .

> 9782 - Centring mandrel-2- must now be pressed out. 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
Fix piston and connecting rod in place using > 9782 - centring mandrel .

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Piston with connecting rod
Fit the piston pin.
Coat the piston pin with new engine oil and push it onto > 9777 - disassembly tool .

Secure the tool at the front hexagon knob cap -1- and turn it anti-clockwise -Arrow- as far as it will go at the rear hexagon knob cap -2- .

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Piston pin on tool 9777

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

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

Turn the tool clockwise at the rear hexagon knob cap 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).
Insert a new piston-pin circlip -1- into > 9776 - assembly tool .
Turn the groove for the small hook on the tool -2- towards the observer.

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Piston-pin circlip in tool 9776

Press the edges together and push the new circlip -1- into > 9776 - the assembly tool .

Position small hook facing the groove -Arrow- .

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Small hook facing groove

Turn the circlip -1- as required.

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Circlip in tool

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

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Circlip in assembly position

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).
Fit circlip -1- on the piston.
Check the position of the circlip -1- .

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Circlip in tool

> 9776 - Assembly tool-1- must be inserted into the assembly bore -Arrow- .

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Guiding tool 9776 into the assembly bore

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

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Small hook at 11 o'clock position

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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Tool tube 9776

Press pipe of tool against the piston and hold securely.

Carefully tap the push rod slightly towards the piston with the ball of your hand until a distinct noise can be heard.

> 9776 - Assembly tool must now be removed.

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 the position of the piston-pin circlip using a mirror
Turn con-rod journal for cylinder 2 to assembly position.
Use > 9773 - turning device to turn the crankshaft to position -F- bottom dead centre -UT 2/5- at the vibration damper.

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Disconnecting vibration damper

Repeat steps 5.2 to 11.2 for cylinder 2.
Turn con-rod journal for cylinder 1 to assembly position.
Use > 9773 - turning device to turn the crankshaft to position -D- bottom dead centre -UT 1/4- at the vibration damper.

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Vibration damper

Repeat steps 5.2 to 11.2 for cylinder 1.

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
Install screw plug -1- .

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Screw plug

Replace O-ring.

Screw in and tighten screw plug -1- .

> Tightening torque 80 Nm (59 ftlb.)
Insert guide rail for cylinders 1 to 3, screw in short bearing pin -1- and tighten.
> Tightening torque 10 Nm (7.5 ftlb.)

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Installing guide rails
Insert oil return (oil windage tray) -1- and fit and tighten screws -2- .
> Tightening torque 13 Nm (9.5 ftlb.)

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Oil guide (oil plate)