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Piston with Con-rod, Remove and Install
 Remove
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Remove cylinder heads – see operation "Cylinder Heads for
Cylinders 1-3-5 and 2-4-6, Remove and Install".
Remove oil baffle plate – see operation "Oil Baffle Plate,
Remove and Install".
Mark order of con-rod bearing caps – bead (1) of con-rod
bearing caps points to transmission side. Remove con-rod bearing
cap from con-rod.
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Caution
The broken surfaces of con-rod and con-rod bearing cap
constitute to individual fit and must not become mixed up or
damaged. To prevent damage – do not lay con-rods and con-rod
bearing caps on their broken surfaces.
Remove
Remove combustion residue from upper part of cylinder bore.
Remove piston with con-rod upwards from cylinder bore.
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 Clean
Inspect
Clean and check all parts, replace if necessary.
Note: For the X 25
XE, the piston pin is pressed into the con-rod. Disassembly is not
possible. Piston, con-rod and piston pin can only be replaced
together. For the Y 26 SE, X 30 XE and Y 32 SE, the piston pin is
mounted so that it floats in the con-rod.
Install
Insert new piston rings with
identification "TOP" on top in piston using piston ring pliers.
Note position of piston ring gaps!
| 1. |
2nd compression ring |
| 2. |
Steel band ring (oil scraper ring –
upper) |
| 3. |
Steel band ring (oil scraper ring –
lower) |
| 4. |
1st compression ring |
| 5. |
Intermediate ring (oil scraper ring) |
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Caution
Contact surfaces (1) and (2) of con-rod and con-rod bearing cap
must be in perfect and clean condition. If the contact surfaces are
damaged, the piston and con-rod must be replaced, as to accurate
fit is no longer guaranteed.
Clean contact surfaces with compressed air.
 Adjust
Before inserting con-rod journal of crankshaft, set to BDC
position and coat with engine oil.
Install
Coat piston rings with engine oil and compress with piston ring
tensioner. Push piston into cylinder bore with hammer handle.
Caution
Note installation position. Arrow (3) on piston head points to
engine timing side.
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Install
Note sequence of con-rod bearing caps.
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Con-rod bearing cap – bead (1) of con-rod bearing caps
points to transmission side.
Con-rod bearing cap with new bolts to con-rod – 35 Nm / 26
lbf. ft. + 45° + 15°.
Install oil baffle plate – see operation "Oil Baffle
Plate, Remove and Install".
Install cylinder heads – see operation "Cylinder Head for
Cylinders 1-3-5 and 2-4-6, Remove and Install".
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