Installing all pistons with connecting rod

NOTE: The description is for one component only. The procedure is identical for all further components.

Installing piston with connecting rod

NOTE: RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.

Carefully shift the piston and connecting rod in the engine block.

Aligning piston rings

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Align the contact points of all piston rings twisted by 120° each.

The piston ring gaps must not be positioned in line with the axis of the piston pin (A).

Piston ring	Alignment
Lower oil scraper ring (O3)	12 o'clock position (1)
Spring (O2)	4 o'clock position (2)
Upper oil scraper ring (O1)	8 o'clock position (3)
Central piston ring (K2)	12 o'clock position (1)
Upper piston ring (K1)	4 o'clock position (2)

Make sure that the spring (O2) does not overlap the piston ring gap (1).

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Coat the pistons (1) and piston rings lightly with oil.
Insert the pistons (1) with the piston rings into the connector 0 495 373 (11 6 240).
Screw special tool 0 496 144 (11 8 860) on at large connecting rod eye (2).

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Align the piston so that the arrow (1) points to cylinder 1.
Insert the piston with the connecting rod into the special tool 0 495 373 (11 6 240) and guide it into the cylinder.
NOTE:
RISK OF DAMAGE
Damage on the cylinder wall and oil spray nozzles.
A large force can scratch the cylinder wall and bend the oil spray nozzles.
- Carefully shift the piston and connecting rod in the engine block.
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Push in piston by hand with only little force. Do not use striking tools.
Install the lower connecting rod bearing
Vacuum the connecting rod bearing shell and cracked surface (1) with a vacuum cleaner (2).

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Insert the connecting rod bearing shell (1) into the connecting rod bearing cap (2).
Apply a light coat of oil to the connecting rod bearing shell (1).

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If necessary, screw the inlet guide 0 496 144 (11 8 860) into the large connecting rod eye.
Pull the connecting rod up to the connecting rod bearing journal.

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NOTE:
RISK OF DAMAGE
Engine damage caused by incorrectly installed bearing shells and bearing brackets.
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur.
- Always install all bearing shells and bearing brackets in the same position from which they were removed.
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Attach the connecting rod bearing caps to the connecting rod until the designations (1) match.
Make sure that the connecting rod bearing (2) is attached to the same connecting rod that it was detached from.
A mixed installation of the connecting rod bolts (A) and (B) on a connecting rod bearing cap is not permissible.

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NOTE: TECHNICAL INFORMATION
When installing new connecting rod bolts, you must ensure that two connecting rod bolts are always used on one connecting rod bearing cap.
Mixed installation of various connecting rod bolts on one connecting rod bearing cap is not permitted.
Replace screws (1).

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Tighten the screws.

Make sure that the connecting rod bearing cap (2) rests completely on the connecting rod.

TIGHTENING TORQUES SPECIFICATION

Connecting rod bearing cap to connecting rod
Replace screws. Tighten screws crosswise.	Joining torque	20 Nm
	1. Angle of rotation	70°
	2. Angle of rotation	70°

Follow-up work

Refer to INSTALLING THE OIL DEFLECTOR
Refer to INSTALL THE OIL VACUUM PUMP
Refer to REFITTING ENGINE OIL PAN .
Refer to TIGHTENING THE OIL DRAIN PLUG .
Refer to CLEAN SEALING SURFACES .
Refer to INSTALLING THE CYLINDER HEAD GASKET .
Refer to INSTALLING THE CYLINDER HEAD .
Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF THE FIRST CYLINDER (AUTOMATIC TRANSMISSION) .
Refer to BLOCKING THE CAMSHAFTS .
Refer to INSTALLING THE INTAKE ADJUSTER .
Refer to INSTALL EXHAUST CAMSHAFT ADJUSTER .
Refer to PRELOAD TIMING CHAIN .
Refer to TIGHTENING THE VANOS CENTRAL VALVE .
Refer to CRANK ENGINE TWICE (AUTOMATIC TRANSMISSION) .
Refer to DISASSEMBLING ALL SPECIAL TOOLS
Refer to INSTALL THE COOLANT FEED LINE (COOLANT RETURN LINE IS REMOVED) .
Refer to INSTALL THE REAR SECTION OF THE COOLANT RETURN LINE (FRONT SECTION REMOVED) .
Refer to INSTALL THE FRONT SECTION OF THE COOLANT RETURN LINE .
Refer to INSTALLING THE AUXILIARY COOLANT PUMP .
Refer to INSTALLING THE INTAKE PLENUM .
Refer to INSTALLING THE TANK VENT VALVE .
Refer to TIGHTENING THE OIL FILTER CAP .
Refer to SECURING THE OIL FEED LINE TO THE ENGINE BLOCK .
Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING THE SUPPORT FOR THE EXHAUST TURBOCHARGER .
Refer to INSTALLING STARTER MOTOR .
Refer to INSTALLING CYLINDER HEAD COVER .
Refer to INSTALLING THE INJECTORS FOR THE CYLINDERS 4 TO 6 .
Refer to INSTALLING THE INJECTORS FOR THE CYLINDERS 1 TO 3 .
Refer to PREPARE FOR THE INSTALLATION OF THE HIGH PRESSURE PUMP .
Refer to INSTALL HIGH PRESSURE PUMP .
Refer to INSTALL THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE RAIL AND THE HIGH-PRESSURE PUMP .
Refer to INSTALLING THE IGNITION COILS .
Refer to INSTALL FRONT ENGINE ENCAPSULATION .
Refer to INSTALL BOTH ACTUATORS (ENGINE REMOVED)
Refer to INSTALL CHARGE AIR LINE
Refer to INSTALL BOTTOM CLEAN AIR PIPE .
Refer to INSTALL FRONT AXLE DIFFERENTIAL
Refer to INSTALL BEARING BRACKET
Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG
Refer to TOPPING UP THE MOTOR OIL
Refer to INSTALL CATALYTIC CONVERTER .
Refer to REPLACING THE OXYGEN MONITOR SENSOR
Refer to REPLACING THE LAMBDA OXYGEN SENSOR
Refer to CHECK ENGINE OIL LEVEL .
Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .