REMOVAL AND INSTALLATION



Removal steps


1.
 Oil spray jet

>>E<<
 2.
 Conrod bearing cap

>>D<<
 3.
 Bearing shell
<<A>>
 >>C<<
 4.
 Piston and conrod

>>C<<
 5.
 Piston rings


6.
 Circlip

>>B<<
 7.
 Piston pin

>>A<<
 8.
 Piston


9.
 Conrod


10.
 Cylinder block

REMOVAL SERVICE POINT

<<A>> PISTON AND CONROD REMOVAL
Remove piston and conrod from cylinder block.
note Mark cylinder allocation "A" with coloured pen.

INSTALLATION SERVICE POINT

>>A<< PISTON INSTALLATION
note
  • Arrow on piston crown points to pulley end.
  • Install using piston ring clamp.
  • Cracks on piston skirt, renew piston.

Arrow points towards No. 1 cylinder "arrows."

>>B<< PISTON PIN INSTALLATION
Install piston pin to piston.
note If difficult to remove, heat piston to 60°C.

>>C<< PISTON RING INSTALLATION
Install piston ring to piston.
note
  • Offset gaps by 120°.
  • Remove and install using piston ring pliers.
  • "TOP" faces towards piston crown.

>>D<< BEARING SHELL INSTALLATION
Install bearing shell to conrod and bearing cap.
note
  • Note installation position.
  • Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identification: Black line on bearing surface in area of joint.
  • Do not interchange used bearing shells.
  • Insert bearing shells centrally.
  • Check for secure seating.

>>E<< CONROD BEARING CAP INSTALLATION
Install conrod bearing cap to conrod.
note
  • Installation position: MarKing "B" faces towards pulley end.
  • Note installation position
  • Caps fit only in one position and only on the corresponding con-rod due to breaking procedure (cracking) for separating cap from con-rod.