Piston/cylinder liner - r r

Operation 1028H54 · Pistons and connecting rods

1.2 16v

Dismantling

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

1.4 16v

Dismantling

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

1.6 16v

Dismantling

1. Remove the gudgeon pin circlips.

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

1.8 16v

Dismantling

1. Remove the circlips.

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

2.4 20v

Dismantling

1. Remove the circlips.

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

1.9 JTD 8v

Dismantling

1. Remove the circlips.

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

1.2 16v

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

1.4 16v

1. To remove the pin from the piston, tool (1a) must be modified to reduce diameter (1b) by 1.3 mm as shown in the figure.

1.6 16v

Reassembling

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

1.8 16v

Reassembling

Assemble the connecting rod to the piston 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.

2.4 20v

Reassembling

Assemble the connecting rod to the piston 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.

1.9 JTD 8v

Reassembling

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 secure them using the circlips.

1.2 16v

Reassembling

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.

1.4 16v

1. Position the connecting rod - piston assembly on mount (1a), then use a hydraulic press and the tool modified previously to remove pin (1b) from the piston.

1.6 16v

Fit the gudgeon pin in its housing.

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

1.2 16v

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

1.4 16v

Reassembling

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.

1.2 16v

1. Test the gudgeon pin fit locking the connecting rod-piston assembly in the supporting tool (1a) and positioning a dial gauge for measuring the movement of the pin.

2. Act on 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 pointer on the dial gauge returns to zero. If this is not the case, replace the connecting rod.

1.4 16v

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

1.2 16v

Fit the seals on the piston using the special tool.

The second seal is fitted with the word TOP facing upwards.

When the fitting is completed, position the notches in the seals so that they are not aligned with the the gudgeon pin axis and are offset from one another by 120°.

1.4 16v

1. Test the gudgeon pin fit locking the connecting rod-piston assembly (1a) in the supporting tool (1b) and positioning a dial gauge for measuring the movement of the pin.

2. Act on 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 pointer on the dial gauge returns to zero. If this is not the case, replace the connecting rod.

Fit the seals on the piston using the special tool.

The second seal is fitted with the word TOP facing upwards.

When the fitting is completed, position the notches in the seals so that they are not aligned with the the gudgeon pin axis and are offset from one another by 120°.