 Remove, Disconnect Remove piston - see operation "Piston with Con-rod, Remove and Install". Piston pin retaining ring using screwdriver, piston pin with brass rod and light hammer blows.
 Inspect Check piston pin for wear and other faults. Permissible piston pin outer diameter: 26.995 - 27.000 mm. | 
|
 Measure Measure interior diameter of the con-rod piston pin bushing. Permissible clearance between piston pin and piston pin bushing:
|
New |
0.008 to 0.020 mm. |
|
Run-in |
max. 0.050 mm. |
Measure inner diameter of piston pin bore in piston. Permissible clearance between piston pin and piston bore: 0.002 to 0.012 mm
Inspect Coat piston bore with engine oil and check whether piston pin can be pushed into piston bore by hand and without jamming. | 
|
Measure Measure outer diameter of piston perpendicularly to piston pin bore, approx. 60 mm/2.4 in. below piston head. Permissible outside diameter: 78.975 to 79.004 mm.
|
Measure cylinder bore with inside micrometer at the |
|
levels |
1 = 12 mm |
|
|
2 = 55 mm |
|
|
3 = 95 mm |
|
in each case axially and radially to the crankshaft. Permissible cylinder bore diameter: |
|
Identification |
Cylinder bore in mm |
|
A |
79.000 to 79.009 |
|
B |
79.010 to 79.019 |
|
C |
79.020 to 79.029 |
Notice: If the range of tolerance is exceeded, all cylinders must be rebored. | 
|
 Install, Connect Insert con-rod in piston. Front marks on con-rod and piston (arrows) must point towards timing gear side of engine. Lubricate piston pin, piston pin bore and con- rod bore thoroughly and press in piston pin by hand. Insert new piston pin snap rings on both sides.
 Important! The weight difference between the four con-rods fitted with pistons and piston rings must not exceed 4 g. | 
|
|
