Connecting rod and piston set - r r

Operation 1028H10 · PISTONS AND CONNECTING RODS

Refer to op. 1028H20 piston with connecting rod - r r

Refer to op. 1004E20 engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and oil sump - does not include repairs to cylinder head and auxiliary unit.

Removing

Position the car on the ramp.

Drain the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge.

Carry out - 4450B04 right front wheel r r.

Carry out - 7055B54 under-engine guard - r r.

Carry out.

Carry out - 5530B10 battery - r+r.

Carry out - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Carry out - 1060G90 diesel injection wiring harness - r r.

Carry out - 1016B10 single cylinder head extension - change gasket.

Carry out - 1016C10 cylinder head - r + r and replace gasket.

Carry out - 2110A60 manual gearbox/engine coupling bracket - r+r.

1. Undo the drain plug on the engine sump and drain the oil fully into a suitable container.

Do not disperse the oil into the environment, as indiscriminate dispersal of this product causes pollution.

Refer to op. 1028H20 piston with connecting rod - r r

Removing

- 1028H20 piston with connecting rod - r r bearing in mind that all the cylinders should be worked on.

1. Undo nuts (1a) and bolts (1b) securing the oil sump to the crankcase.

2. Use the tool to cut the crankcase sump sealant.

3. Remove the crankcase sump.

Refitting

- 1028H20 piston with connecting rod - r r bearing in mind that all the cylinders should be worked on.

1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b).

Remove the pin previously fitted from the hole in the gearbox.

1. Adjust the bolt securing the pulley mount flange to the crankshaf to rotate the crankshaft until the pistons for cylinders 1 and 4 are at B.D.C.

2. Undo bolts (2a) and remove big end bearing caps (2b) complete with bearing shells (2c) for cylinders 1 and 4.

1. Release and remove the piston-connecting rod assemblies (1a), complete with half-bearings (1b) for cylinders 1 and 4.

Follow the same procedure to remove the piston-connecting rod assemblies for the 2nd and 3rd cylinders.

Refitting

Clean any sealant residues from the matching surfaces between the lower engine crankcase and the crankcase sump.

Fit the piston-connecting rod assemblies in accodance with the following references.

1. Piston category (1a) and arrow (1b) indicating timing side.

2. Area where number of cylinder bore/liner to which the connecting rod belongs is stamped.

3. Drain (3b) on the piston skirt must be aligned with oil spray (3b).

1. Place the piston-connecting rod assemblies for the 2nd and 3rd cylinders, complete with half-bearings back in their housings using a suitable fitting tool.

The big end bearing shells can be identified as follows:

upper big end bearing shells, dark coloured three metal connecting rod side;

lower big end bearing shells, light coloured two metal cap side with an opening.

1. Fit the cylinder 2 and 3 connecting rod caps (1a), complete with half-bearings (1b), and secure by tightening the bolts (1c) to the recommended torque.

The big end bearing shells can be identified as follows:

upper big end bearing shells, dark coloured three metal connecting rod side;

lower big end bearing shells, light coloured two metal cap side with an opening.

Use the tool for angular tightening of the connecting rod cap bolts.

Follow the same procedure when fitting the piston-connecting rod assemblies for the 1st and 4th cylinders.

Fit a suitable pin through the hole in the gearbox.

Place the crankcase oil sump partition back in its housing and secure it using the bolts.

1. Apply a bead of recommended silicone sealant to the contact surfaces of the crankcase sump and the lower engine crankcase as illustrated in the diagram below.

No breaks are allowed in the sealant strip. Sealant strip diameter must be 3.5 0.5 mm.

1. Place the crankcase sump (1a) back in its housing and secure it by tightening the bolts (1b) and the nuts (1c) to the recommended torque.

1. Tighten the crankcase sump drain plug to the recommended torque.

Carry out - 2110A60 manual gearbox/engine coupling bracket - r+r.

Carry out - 1016C10 cylinder head - r + r and replace gasket.

Carry out - 1016B10 single cylinder head extension - change gasket.

When the bolts fixing the timing cover to the single camshaft housing are being tightened, tighten the bolts fixing it to the cylinder head as well.

Carry out - 1060G90 diesel injection wiring harness - r r.

Carry out - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Carry out - 5530B10 battery - r+r.

Refill the engine oil lubrication system - 0010T11 engine oil check level and top up.

Refill the engine cooling system with coolant - 0010T20 coolant change.

Carry out.

Carry out - 7055B54 under-engine guard - r r.

Carry out - 4450B04 right front wheel r r.

Fill the air conditioner coolant circuit - 0010T84 coolant for air conditioning system dehydrate and recharge.

Remove the car from the ramps.