Piston/cylinder liner - r r

Operation 1028H54 · Pistons and connecting rods

1.1

Dismantling

1. Remove the gudgeon pin circlips.

2. Withdraw the pin (2a) using a hydraulic press, the support (2b) and a suitable puller (2c).

3. Separate the piston (3a) from the connecting rod (3b).

1.2 8v

Dismantling

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

1.3 JTD 16v

Dismantling

1. Remove the circlips.

2. Remove the pin (2a) and separate the connecting rod (2b) from the piston (2c).

1.1

Reassembling

Heat the connecting rods in an oven to a temperature of around 240 ° C to allow the fitting of the gudgeon pin.

1. Join the connecting rods to the pistons so that the gudgeon pin offset is facing the number stamped on the big end.

1.2 8v

1. Fit the connecting rod-piston assembly on the tool (1a) then, using a hydraulic press and a suitable drift, extract the pin (1b) from the piston.

1.3 JTD 16v

Reassembling

1. Join the connecting rods to the pistons so that the number stamped on the big end (1a) is facing the reference (1b) on the piston skirt where the oil jet is housed.

Fit the pins and secure them using the circlips.

1.1

1. Fit the gudgeon pin (1a) working in a vice and using the fitting tool (1b).

1.2 8v

Reassembling

Heat the connecting rods in an oven to a temperature of around 240 ° C to allow the fitting of the gudgeon pin.

1. Join the connecting rods to the pistons so that the gudgeon pin offset is facing the number stamped on the big end.

1.1

Secure the gudgeon pin with the circlips.

1.2 8v

1. Fit the gudgeon pin (1a) using the tool (1b) working in the vice with the connecting rod supported by the tool (1c).

Fit the gudgeon pin in the direction shown by the arrow on the piston crown.

1. Test the gudgeon pin fit locking the connecting rod-piston assembly in the supporting tool (1a) and positioning a dial gauge for measuring the movement of the pin.

2. Act on the tool nut using a torque wrench set at a torque of 1.27 daNm equal to an axial load of 392.4 daN. The matching is correct if, when the action of the torque wrench is over and the nut is returned to its original simple contact position, the pointer on the dial gauge returns to zero. If this is not the case, replace the connecting rod.

Fit the seals on the piston using the special tool.

The second seal is fitted with the word TOP facing upwards.

When the fitting is completed, position the notches in the seals so that they are not aligned with the the gudgeon pin axis and are offset from one another by 120°.