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Fitting of pistons (in situ)

Fitting of 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 stamped on the inside of the piston. Observe the strictest cleanliness.



1. Assemble piston and connecting rod by driving in the gudgeon pin using a plastic mallet and drift. Make sure that the marking on the piston faces the timing cover and that the numbers on the connecting rod face the exhaust side. Take care to avoid damaging the piston and connecting rod.

2. Fit the gudgeon pin circlips.

Warning

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


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

4. Fit protective sleeves (75 19 531) over the connecting rod studs and oil the piston rings, bearings and cylinder.

5. Fit the piston, using piston installing tool 78 62 287.


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

Tightening torque 48 Nm (35.5 lbf ft)

7. Check that there are no impurities or other foreign matter in the sump and make sure that its flange is scrupulously clean. Use Benzine.


8. Apply an even bead of flange sealant, part no. 93 21 795, to the sealing surface of the oil sump and fit the oil sump.

Tightening torque: 22 Nm (16 lbf ft).

9. Refit the cover plate.

10. Offer up the sub-frame and bolt it in place.


Tightening torques

front 115 Nm (85 lbf ft)

middle 190 Nm (140.6 lbf ft)

- rear 110 Nm + 75° (81 lbf ft + 75°).

11. Fit the nuts securing the end pieces and tighten them.

Tightening torque: 75 Nm (55.5 lbf ft).

12. Clean the exhaust pipe joints.


13. Fit the bolt securing the catalytic converter to the bracket on the engine but do not tighten it. Screw the front exhaust pipe to the exhaust manifold or turbocharger. Before assembly, apply Molycote 1000 to the threaded studs on the turbocharger.

14. Tighten the bolt securing the catalytic converter to the bracket on the engine and screw together the joints under the car.

15. Fit the spoiler sections and road wheels.

Tightening torque, wheel bolts 110 Nm (81 lbf ft).

16. Lower the car, connect the oxygen sensor leads and remove the lifting beam.