CONNECTING ROD AND PISTON SET - R.R

Operation 1028H10 · PISTONS AND CONNECTING RODS

2.2 JTS

Removing

- Position the vehicle on a lift.

Op. 1084A16 OIL DIPSTICK PIPE - R.R

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 1020A20 CRANKCASE OIL SUMP - R.R CLEAN SURFACES FOR SEALANT APPLICATION

Op. 1048A34 SLEEVE(S) FROM FLOW METER TO AIR SUPPLY CAPACITY CASE - R + R

Op. 1056F17 THROTTLE BODY WITH DVL R R

Op. 1072B50 AIR CHAMBER - R.R.

Op. 1072B54 HOSES CONNECTING AIR INTAKE CHAMBER TO INTAKE MANIFOLD(S) - R.R.

Op. 1072B21 AIR INTAKE FUEL MANIFOLD INTERGRATED DUCT R R AND REPLACE GASKET

Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R

Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R

Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R

Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

- Rotate the engine until the pistons for cylinders 1 and 4 are at B.D.C.

- Undo the bolts and remove the connecting rod caps complete with 1st and 4th cylinder lower connecting rod half-bearings.

Push the connecting rods upwards until the pistons are above the cylinder block/crankcase.

Take care not to damage the cylinder liner/bore during the removal of the pistons.

- Lower the vehicle.

- Release and remove the connecting rods and pistons and upper connecting rod half-bearings for cylinders 1 and 4.

- Carry out the same operations for the removal of the connecting rods and pistons for cylinders 2 and 3.

Refitting

- Fit the connecting rods and pistons and upper connecting rod half-bearings for cylinders 2 and 3 using a suitable fitting tool.

- Raise the vehicle.

- Fit the connecting rod caps complete with the half-bearings for cylinders no. 2 and 3 and secure them tightening the bolts to the recommended torque.

- Carry out the same operations for the refitting of the connecting rods and pistons for cylinders 1 and 4.

Op. 1016C10 SINGLE CYLINDER HEAD - R.R. AND REPLACE GASKET

Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R

Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R

Op. 1048A28 VACUUM AIR CIRCUIT RESONATOR PIPE - R+R

Op. 1072B21 AIR INTAKE FUEL MANIFOLD INTERGRATED DUCT R R AND REPLACE GASKET

Op. 1072B54 HOSES CONNECTING AIR INTAKE CHAMBER TO INTAKE MANIFOLD(S) - R.R.

Op. 1072B50 AIR CHAMBER - R.R.

Op. 1056F17 THROTTLE BODY WITH DVL R R

Op. 1048A34 SLEEVE(S) FROM FLOW METER TO AIR SUPPLY CAPACITY CASE - R + R

Op. 1020A20 CRANKCASE OIL SUMP - R.R CLEAN SURFACES FOR SEALANT APPLICATION

Op. 1092G10 SINGLE ENGINE BELT - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B04 RIGHT FRONT WHEEL - R.R

Op. 1084A16 OIL DIPSTICK PIPE - R.R

Op. 0010T71 POWER STEERING FLUID CHECK LEVEL AND TOP UP IF NECESSARY

Op. 0010T11 ENGINE OIL - CHECK LEVEL AND TOP UP, IF NECESSARY

Op. 0010T75 HYDRAULIC POWER STEERING SYSTEM BLEED AIR

- Remove the vehicle from the lift.

3.2 JTS

2.4 JTD 20v

- On this car, it is not possible to remove/refit the pistons with the connecting rods on the car.

To perform this operation, remove/refit the power unit

Op. 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

and then work at the bench, customising the engine service procedures for this operation.