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Piston with connecting rod, removing and fitting

Piston with connecting rod, removing and fitting

To remove



1. Remove the oil pan - see Oil pan, removing and fitting .

2. Remove the oil intake pipe (1) from the oil pump and the engine block.

3. Remove the cylinder head - see Cylinder head, removing and fitting .

Note

Mark the order of the big-end bearing caps.


4. Remove the big-end bearing cap from the connecting rod.

The fracture surfaces of the connecting rods and the big-end bearing caps form an individual fit and must not be interchanged or damaged. Do not rest the connecting rods or big-end bearing caps on their fracture surfaces to avoid damage.

5. Remove combustion residue from the top part of the cylinder bore.


Changing, cleaning


1. Press out the piston together with the connecting rod upward from the cylinder bore.

2. Check and clean all parts, change them if necessary. Change the piston - see Piston, change .

3. Put the crankshaft big-end journal in "ND position" and moisten it with engine oil.

Adjust the piston ring positions:

4. Oil scraper ring II: offset the steel ring gaps 25 to 50 mm to the left and right of the middle ring gap respectively. Piston ring I: offset the ring gap about 180°. Second piston ring with "TOP" face up.


5. Moisten the piston rings with engine oil and compress them with a normal piston ring compressor.


6. Push the piston into the cylinder bore with the handle of a hammer.

Caution

Note the fitting position of the piston and connecting rod.

7. The arrow (1) on the bottom of the piston pointing towards the timing end of the engine, the boss (2) on the connecting rod towards the gearbox end.


To fit


1. Note the order of the big-end bearing caps.


2. Fit the big-end bearing caps - boss (1) on the big-end bearing cap pointing towards the gearbox end.

3. Big-end bearing cap with new bolts on connecting rod - tightening torque 25 Nm + 30°.

4. Fit the oil intake pipe (2) together with a new sealing ring on the oil pump - tightening torque 8 Nm

Note

Recut the threads before reuse and apply locking compound (red) when fitting the bolts. Mounting time including checking torque must not exceed 10 min.


5. Fit the oil intake pipe onto the engine block - tightening torque 8 Nm.

6. Fit the oil pan - see Oil pan, removing and fitting .

7. Fit the cylinder head - see Cylinder head, removing and fitting.