Piston and Connecting Rod Inspection for 300Tdi Engine
ENGINE
68
OVERHAUL
3. Starting with number 1 piston, invert piston and
with arrow on piston crown pointing towards
REAR of cylinder block, insert piston into
number 1 cylinder bore until bottom of skirt is
30 mm from top of bore.
4. Using feeler gauges, check clearance between
left hand side of piston and cylinder bore =
0.075 mm( viewed from front of cylinder block
).
5. Repeat above procedures for remaining
pistons. If piston to cylinder bore clearance for
any piston exceeds figure given, cylinder block
must be rebored.
6. Measure gudgeon pin diameter at each end
and centre of pin.
Diameter = 30.156 to 30.162 mm
7. Renew gudgeon pin and piston as an
assembly if diameter is less than specified or if
excessive pin to piston clearance is evident.
8. Check small end bushes for signs of wear or
overheating, check that gudgeon pins are a
tight, sliding fit in the bushes with no
perceptible side play.
CAUTION: Small end bushes cannot be
replaced, a new connecting rod must be
fitted.
9. Using the fingers only, check that a new
big-end bearing cap nut runs freely on each
connecting rod bolt; if any nut is tight on the
threads, renew both bolts on that connecting
rod.
CAUTION: Retain nuts with their
respective connecting rod bolts.
10. Check connecting rods for alignment -
maximum = 0.127 mm per 25.4 mm of length.
Replace any rod which is misaligned.
