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Fitting pistons (in situ)

Fitting pistons (in situ)

(Cylinder head removed)


Important

Pistons of different makes must not be used in the same engine. The name of the manufacturer is cast inside the piston.



1. Assemble piston and connecting rod by driving in the gudgeon pin, using a plastic mallet and drift. Make sure that the mark on the piston crown faces the timing cover and that the numbers on the connecting rods face the exhaust side.

2. Fit the gudgeon pin lock ring.

Warning

It is extremely important to fit the lock ring with its opening upwards.


3. Place the bearing shells in place in the connecting rods.

4. Fit protective sleeves, part no. 75 19 531, on the connecting rod studs and oil the piston rings, bearings and cylinder.

5. Fit the piston using the fitting tool, part no. 78 62 287.


6. Fit the big-end bearing caps with bearing shells (connecting rod numbers facing in the same direction).

Tightening torques:

20 Nm + 70° (14.8 lbf ft + 70°)

7. Check that there are no impurities or other foreign matter in the sump and clean the sealing surfaces with benzine.


8. Apply an even bead of Loctite 518 on the sealing surface of the oil sump and fit the oil sump.

Tightening torque: 22 Nm (16.2 lbf ft).

9. Fit the protective plate.

10. Lift up the subframe and bolt it in place.


Tightening torques:

Front: 115 Nm (85 lbf ft)

Centre: 190 Nm (140.6 lbf ft)

Rear: 110 Nm + 75° (81.4 lbf ft + 75°)

11. Fit and tighten the end piece nuts.

Tightening torque: 75 Nm (55.5 lbf ft)

12. Clean the area for the joint in the exhaust pipe.


13. Fit the front exhaust pipe. Lubricate the stud screws on the turbocharger with Molycote 1000 before fitting.

14. Screw together the joint between the front and intermediate exhaust pipes.

15. Fit the air shields and wheels.

Tightening torques:

Wheels: 120 Nm (89 lbf ft)

16. Make sure the oil drain plug is tight, lower the car and fill with engine oil. Replace the dipstick, connect the oxygen sensor cable and remove the lifting beam