Piston, pin set - replace

Operation 1028H60 · PISTONS AND CONNECTING RODS

1.2 8v

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH

1.6 16v

Clean any carbon residues from the piston crown.

Check that the weight difference between the pistons corresponds to the recommended figures.

Slight machining in the internal piston areas for equalizing the weight is permitted.

Check the connecting rod alignment using a sample pin.

If the connecting rod is not aligned, replace it.

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH.

Removing

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH

operation to be carried out on the entire set of pistons.

1. Use pliers (1a) to remove the piston rings (1b) from the piston.

Refitting

Clean any carbon residues from the piston crown.

1. Check that the weight difference between the pistons corresponds to the recommended figures.

2. Slight machining in the areas for equalizing the weight is permitted.

Check the connecting rod alignment using a sample pin.

If the connecting rod is not aligned, replace it.

Using the same pliers, fit the circlips on the pistons.

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH

operation to be carried out on the entire set of pistons.

1.3 JTD 16V

Removing

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

1. Remove the piston rings (1a) from the pistons using a suitable tool (1b).

The maximum permitted opening for the ring is 28 mm.

Refitting

Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.

Check that the weight difference between the pistons corresponds to the recommended figures.

Check that the weight difference between the connecting rods, complete with half-bearings, caps and bolts corresponds to the recommended figures.

Fit the piston rings on the pistons using the tool.

The maximum permitted opening for the ring is 28 mm.

1. Join the connecting rods to the pistons so that the number printed on the connecting rod big end (1a) is facing in the opposite direction to the notch (1b) on the piston skirt for the oil jet housing.

Fit the pins and secure them using the circlips.

1.9 DIESEL

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

1. Remove the piston rings (1a) from the pistons using the tool (1b).

Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.

Check that the weight difference between the pistons corresponds to the recommended figures.

The arrows in the diagram illustrate where material can be removed from the to equalize the weight.

Check that the weight difference between the connecting rods, complete with half-bearings, caps and bolts corresponds to the recommended figures.

The arrows in the diagram illustrate where material can be removed from the to equalize the weight.

1.9 JTD 8V

Fit the circlips on the pistons using the tool.

1. Join the connecting rods to the pistons so that the number stamped on the big end (1a) is facing the oil spray (1b) undercut on the piston.

Fit the pins and secure them using the circlips.

Removing

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

1. Remove the piston rings (1a) from the pistons using the tool (1b).

Refitting

Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.

Check that the weight difference between the pistons corresponds to the recommended figures.

The arrows in the diagram illustrate where material can be removed from the to equalize the weight.

Check that the weight difference between the connecting rods, complete with half-bearings, caps and bolts corresponds to the recommended figures.

The arrows in the diagram illustrate where material can be removed from the to equalize the weight.

Fit the circlips on the pistons using the tool.

1. Join the connecting rods to the pistons so that the number stamped on the big end (1a) is facing the oil spray (1b) undercut on the piston.

Fit the pins and secure them using the circlips.

1.4 8v

Removing

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH

Refitting

- Clean any carbon residues from the piston crown.

- Check that the weight difference between the pistons corresponds to the recommended figures.

- Slight machining in the internal piston areas for equalizing the weight is permitted.

- Check the connecting rod alignment using a sample pin.

- If the connecting rod is not aligned, replace it.

Op. 1028H54 PISTON WITH CONNECTING ROD - SEPRATION AT THE BENCH