Fitting pistons (in situ)
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Fitting pistons (in situ)
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(Cylinder head removed)
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Important
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Pistons of different makes must not be used in the same engine. The name of the manufacturer is cast inside the piston.
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1.
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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.
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Important
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If one connecting rod is to be changed to a newer type (part no. 91 97 617), all the connecting rods must be changed or the difference in weight will become too great.
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2.
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Fit the gudgeon pin lock ring.
Warning
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It is extremely important to fit the lock ring with its opening upwards.
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3.
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Place the bearing halves in place in the connecting rods.
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4.
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Fit protective sleeves, part no. 75 19 531, on the connecting rod studs and oil the piston rings, bearings and cylinder.
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5.
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Fit the piston using the fitting tool, part no. 78 62 287.
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6.
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Fit the big-end bearing caps with bearing halves (connecting rod numbers facing in the same direction).
Tightening torques:
20 Nm + 70˚ (14.8 lbf ft + 70˚)
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7.
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Check that there are no impurities or other foreign matter in the sump and clean the sealing surfaces with benzine.
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8.
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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 (16.2 lbf ft)
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9.
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Fit the protective plate.
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10.
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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˚)
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11.
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Fit and tighten the end piece nuts.
Tightening torque: 75 Nm (55.5 lbf ft)
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12.
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Clean the area for the joint in the exhaust pipe.
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13.
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Fit the front exhaust pipe. Lubricate the stud on the turbocharger with Molycote 1000 before fitting.
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14.
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Screw together the joint between the front and intermediate exhaust pipes.
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15.
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Fit the air shields and wheels.
Tightening torques:
Wheels: 120 Nm (89 lbf ft)
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16.
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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
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