Piston connecting rod set - r r

Operation 1028H14 · Pistons and connecting rods

1.1

Removing

Rotate the engine on the overhauling stand.

1. Undo the nuts (1a) and bolts (1b) and remove the oil sump (1c).

To facilitate the detachment of the oil sump, heat up the sealant with a bodywork hot air blower.

1.2 8v

Removing

- 1020A24 crank case oil sump - r + r clean seals for sealant application with engine removed

1. Position the flywheel retainer.

2. Undo the fixing bolts (2a) and remove the clutch plate (2b).

1.3 JTD 16v

Removing

1. Undo the bolts (1a) and remove the air conditioning compressor (1b).

1.1

1. Fit the tool for rotating the crankshaft.

Rotate the crankshaft using the tool fitted previously until cylinders no. 2 and no. 3 are at T.D.C.

2. Undo the bolts (2a) and remove the connecting rod caps (2b) for cylinders 2 and 3.

3. Remove the lower connecting rod half bearings for cylinders no. 2 and no. 3.

4. Remove the connecting rod-piston assemblies of cylinders no. 2 and 3.

5. Remove the upper connecting rod half bearings for cylinders 2 and 3.

Proceed in the same way to remove the pistons and connecting rods for cylinders 1 and 4.

1.2 8v

1. Remove the two bolts fixing the engine flywheel and position the tool (1a) for rotating the crankshaft.

Remove the flywheel lock fitted previously.

Rotate the crankshaft using the tool fitted previously until cylinders no. 1 and no. 4 are at T.D.C

2. Undo the bolts (2a) and remove the connecting rod cap (2b) for cylinders 1 and 4.

3. Remove the lower connecting rod half bearings for cylinders no. 1 and no. 4.

4. Remove the connecting rod-piston assemblies for cylinders 1 and 4.

5. Remove the upper connecting rod half bearings for cylinders 1 and 4.

Proceed in the same way to remove the pistons and connecting rods for cylinders 2 and 3.

1.3 JTD 16v

1. Undo the bolts (1a) and remove the air conditioning compressor support (1b).

1.1

Refitting

Rotate the engine on the overhauling stand.

The connecting rod-piston assemblies are fitted with the references in the following positions.

1. Engine rotation arrow stamped on the piston crown (viewed from timing side)

2. Engraving of matching cylinder number

3. Connecting rod pin offset

1.2 8v

Refitting

Rotate the crankshaft using the tool fitted previously.

The connecting rod-piston assemblies are fitted with the references in the following positions.

1. Piston grade and arrow indicating the timing side.

2. Area where number of cylinder bore/liner to which the connecting rod belongs is stamped.

3. Connecting rod pin offset.

1.3 JTD 16v

Rotate the engine through 180° on the overhauling stand.

1. Undo the bolts (1a) and remove the connecting rod caps (1b).

2. Remove the lower big end half-bearings.

1.1

1. Fit the connecting rod-piston assemblies (1a) complete with bearing shells of cylinders no. 1 and no. 4 using the tool (1b).

1.2 8v

1. Fit the connecting rod-piston assemblies (1a), complete with half-bearings, using the tool (1b) for compressing the piston rings and later introducing the piston in the liner/bore.

1.3 JTD 16v

1. Remove the connecting rod-piston assemblies.

2. Remove the upper connecting rod half-bearings.

1.1

Rotate the engine on the overhauling stand.

Fit the connecting rod caps and bearing halves for cylinders 1 and 4 and tighten the bolts to the specified torque.

The connecting rod caps are fitted so that the number stamped on them is facing the same side as the one stamped on the big end.

Do the same to fit the connecting rod-piston assemblies of cylinders no. 2 and no. 3.

Remove the tool for rotating the crankshaft.

1. Apply an unbroken bead of the recommended sealant to the entire perimeter of the crankcase sump as shown in the figure.

Ensure a perfect join between start and end section.

2. Refit crankcase sump (2a) and secure by tightening bolts (2b) and nuts (2c) to the specified torque.

When fitting the crankcase sump, avoid major sideways movements which may remove the sealant.

Wait at least 1 hour after fitting the engine block sump before replenishing it with engine oil.

1.2 8v

Rotate the engine on the overhauling stand.

1. Fit the connecting rod caps (1a), complete with half-bearings (1b), and fix them tightening the bolts (1c) to the recommended torque.

The connecting rod caps are fitted so that the number stamped on them is facing the same side as the one stamped on the big end (inlet side).

1.3 JTD 16v

Refitting

Clean the components removed thoroughly and check their condition through a visual inspection.

Lubricate all the components for the mechanical couplings using engine oil.

Check the crankshaft bearings, taking into account that no adjustment operations should be carried out on half-bearings. If there are signs of grooves or seizing, they must be replaced.

1. Fit the tool.

1.2 8v

Remove the tool for rotating the crankshaft.

Fit the flywheel lock.

Fit the two bolts removed previously fixing the flywheel and tighten them to the recommended torque.

1. Line up the driven plate for fitting the clutch assembly (1a), using the centring pin (1b).

2. Tighten the bolts fixing the clutch to the engine flywheel.

Remove the engine flywheel lock applied previously.

1.3 JTD 16v

Rotate the crankshaft using the tool fitted previously.

The piston-connecting rod assemblies are fitted according to the following references.

1. Piston category (1a) and arrow (1b) indicating timing side.

2. Area where number of cylinder bore/liner to which the connecting rod belongs is stamped.

3. Drain (3b) on the piston skirt must be aligned with oil spray (3b).

1.2 8v

- 1020A24 crank case oil sump - r + r clean seals for sealant application with engine removed.

1.3 JTD 16v

1. Place the connecting rod-piston assemblies (1a) complete with upper connecting rod half-bearings using the tool (1b) back in their housings.

Rotate the engine through 180° on the overhauling stand.

1. Fit the calibrated wire (Plastigage) to measure the big end bearing clearance.

1. Place the big end caps (1a) complete with half-bearings (1b) back in their housings.

2. Tighten the bolts (2a) fixing the connecting rod caps to the recommended torque using the angular tightening tool (2b).

Undo the bolts and remove the connecting rod caps complete with half-bearings fitted previously.

1. Using a suitable graduate measuring instrument (1a), measure the clearance shown by the calibrated wire (1b).

Check one journal at a time without moving the crankshaft.

If the reading is not within the specified range, replace the half-bearings with new ones of the appropriate size and grade.

Proceed with the final fitting of the connecting rod caps tightening the fixing bolts following the previous instructions.

Remove the tool.

1. Place the air conditioning compressor mounting (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

1. Place the air conditioning compressor (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.