Piston, pin set - replace

Operation 1028H60 · Pistons and connecting rods

1.6 TS

1. Remove the circlips

2. Remove the pins (2a) and separate the connecting rods (2b) from the pistons (2c).

3. Remove the piston rings (3a) from the pistons using a suitable tool (3b).

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 connecting rods, complete with half-bearings, caps and bolts, is within the recommended values.

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

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

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

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

Assemble the connecting rods with the corresponding pistons so that the number stamped on the small end faces the large notches (for inlet valves) on the piston crown.

Fit the pin and secure it with its circlips.

2.0 TS

1. Remove the circlips.

2. Remove the pins (2a) and separate the connecting rods (2b) from the pistons (2c).

3. Remove the piston rings (3a) from the pistons using a suitable tool (3b).

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 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.

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.

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

Fit the piston rings on the piston so that the word TOP stamped on them is turned toward the piston crown.

From September 2003, piston rings with a modified profile will be used. The piston ring for the 1st groove and the piston ring for the 2nd groove are the same thickness (1.19 mm); follow the diagram shown below to fit them correctly.

Assemble the connecting rods with the corresponding pistons so that the number stamped on the small end faces the large notches (for inlet valves) on the piston crown.

Fit the pin and secure it with its circlips.

3.2 V6

Dismantling

1. Remove the circlips.

2. Remove the pins (2a) and separate the connecting rods (2b) from the pistons (2c).

3. Remove the piston rings (3a) from the pistons using a suitable tool (3b).

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 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.

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.

Refit the piston rings using a suitable tool

1. Join the connecting rod to the piston so that:

for the left bank, arrow (1a) stamped on the piston is turned toward the same side as the stamp (1b) on the connecting rod;

for the right bank, arrow (1c) stamped on the piston is turned towards the opposite side to the stamp on the connecting rod.

Refit the pin and secure using piston rings.

1.9 JTD 8V

Dismantling

1. Remove the circlips

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

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

Reassembling

Check the alignment of the connecting rods using a suitable tool; if the connecting rods are not perfectly aligned they must be replaced.

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

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

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

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

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

1. Join the connecting rods to the pistons so that the number stamped on the big end (1a) is facing the combustion chamber (1b) in the piston.

Fit the pins and fix them using the circlips.

1.9 JTD 16V

Dismantling

1. Remove the circlips.

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

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

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.

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.

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

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.