Piston/cylinder liner - r r

Operation 1028H54 · PISTONS AND CONNECTING RODS

1.2 8v

1. Remove the seals (1a) from the piston using the tool (1b).

1. Position the connecting rod-piston assembly on the tool (1a) then, using a hydraulic press and a suitable drift, extract the gudgeon pin (1b) from the piston.

Heat the connecting rods in an oven to a temperature of around 240°C to allow the fitting of the gudgeon pin.

1. Join the connecting rods to the pistons so that the gudgeon pin offset is facing the number stamped on the big end.

1. Fit the gudgeon pin (1a) using the fitting tool (1b) working in the vice with the connecting rod supported by the tool (1c).

Fit the gudgeon pin in the direction indicated by the arrow on the piston crown.

1. Check the fitting of the gudgeon pin by securing the connecting rod-piston assembly in the support tool (1a) and positioning a dial gauge to measure the movement of the pin.

2. Adjust the tool nut using a torque wrench set at a torque of 1.27 daNm equal to an axial load of 392.4 daN. The matching is correct if, when the action of the torque wrench is over and the nut is returned to its original simple contact position, the dial gauge pointer returns to zero. If this is not the case, replace the connecting rod.

1.6 16v

Fit the piston rings on the piston using the special tool.

The second seal if fitted with the word TOP upwards.

When the fitting is complete, position the references on the piston rings so that they are not aligned with the gudgeon pin axis and are offset 120° from one another.

Removing

1. Remove the gudgeon pin circlips.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

Refitting

1. Fit the piston on the connecting rod taking care to position it with the arrows (1a) pointing towards the inlet side, in other words the side opposite the stamp (1b) on the connecting rod indicating the cylinder to which it belongs.

Fit the gudgeoon pin in the special housing.

1. Secure the gudgeon pin fitting the circlips using the special tool.

1.3 JTD 16V

Removing

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rod (2b) from the piston (2c).

Refitting

1. Join the connecting rods to the pistons so that the number printed on the connecting rod big end (1a) is facing in the opposite direction to the notch (1b) on the piston skirt for the oil jet housing.

Fit the pins and secure them using the circlips.

1.9 DIESEL

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

1.9 JTD 8V

1. Join the connecting rods with the pistons so that the number stamped on the big end (1a) is facing the oil spray (1b) undercut on the

Fit the pins and secure them using the circlips.

Removing

1. Remove the piston rings.

2. Release the pin (2a) and separate the connecting rods (2b) from the pistons (2c).

Refitting

1. Join the connecting rods to the pistons so that the number stamped on the big end (1a) is facing the oil spray (1b) undercut on the piston.

Fit the pins and secure them using the circlips.

1.4 8v

Removing

1. Remove the seals (1a) from the piston using the tool (1b).

1. Fit the connecting rod-piston assembly to tool (1a), then use a hydraulic press and tool (1b) to remove pin (1c).

Refitting

1. Join the connecting rods to the pistons so that the gudgeon pin offset is facing the number stamped on the big end.

1. Fit the gudgeon pin (1a) using the fitting tool (1b) working in the vice with the connecting rod supported by the tool (1c).