Piston, pin set - replace

Operation 1028H60 · Pistons and connecting rods

1.1

Dismantling

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

1.2 8v

Dismantling

- 1028H54 piston/cylinder liner - r r

1.3 JTD 16v

Dismantling

1. Remove the circlips.

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

1.1

1. Remove the gudgeon pin circlips.

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

1.2 8v

Reassembling

Clean the carbon residues from the piston crown.

Check that the difference in weight between the pistons is within the recommended values.

Slight machining in the inner areas of the piston is permissible to equalize the weight.

Check the connecting rod alignment using a sample pin.

If the connecting rod is out of alignment, replace it.

- 1028H54 piston/cylinder liner - r r.

1.3 JTD 16v

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

Maximum ring opening is 28 mm.

1.1

Reassembling

Check the alignment of the connecting rods using a suitable tool; if the connecting rod is not perfectly aligned, replace it.

1.3 JTD 16v

Reassembling

Check the alignment of the connecting rods using a suitable tool; if the connecting rod is not perfectly aligned, replace it.

Check that the difference in weight between the pistons is within the recommended values.

Check that the difference in weight between the connecting rods, complete with bearing shells, caps and bolts, is within the recommended values.

Fit the piston rings on the pistons using a suitable tool.

Maximum ring opening is 28 mm.

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

Check that the difference in weight between the pistons is within the recommended values.

The arrows in the diagram show the areas from where material can be removed in order to equalize the weight.

Check that the difference in weight between the connecting rods, complete with bearing shells, caps and bolts, is within the recommended values.

The arrows in the diagram show the areas from where material can be removed in order to equalize the weight.

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

Secure the gudgeon pin with the circlips.

Fit the seals on the piston using the tool.

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

On completion of assembly, orientate the notches on the sealing rings so that they do not line up with the gudgeon pin axis, and they are staggered by 120° in relation to each other.