Piston, pin set - replace

Operation 1028H60 · Pistons and connecting rods

1.2 16v

Dismantling

- 1028H54 piston/cylinder liner - r r

1.4 16v

Dismantling

- 1028H54 piston/cylinder liner - r r

1.6 16v

Dismantling

- 1028H54 piston/cylinder liner - r r, operation to be carried out on the entire set of pistons.

1. Using suitable pliers (1a), remove the circlips (1b) from the piston.

1.8 16v

Dismantling

1. Remove the circlips.

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

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

2.4 20v

Dismantling

1. Remove the circlips.

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

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

1.9 JTD 8v

Dismantling

1. Remove the circlips.

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

1.9 JTD 16v

Dismantling

1. Remove the circlips.

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

1.2 16v

Reassembling

Clean the carbon residues from the piston crown.

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

Slight maching in the areas shown in the diagram is permissible to equalize the weight.

1.4 16v

Reassembling

Clean the carbon residues from the piston crown.

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

Slight maching in the areas shown in the diagram is permissible to equalize the weight.

1.6 16v

Reassembling

Clean the carbon residues from the piston crown.

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

2. Slight maching in the areas shown in the diagram is permissible to equalize the weight.

1.8 16v

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.

2.4 20v

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.

1.9 JTD 8v

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

1.9 JTD 16v

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

1.2 16v

Check the connecting rod alignment using a sample pin.

If the connecting rod is out of alignment, replace it.

- 1028H54 piston/cylinder liner - r r.

1.4 16v

Check the connecting rod alignment using a sample pin.

If the connecting rod is out of alignment, replace it.

- 1028H54 piston/cylinder liner - r r

1.6 16v

Check the connecting rod alignment using a sample pin.

If the connecting rod is out of alignment, replace it.

Using the same pliers, fit the circlips on the piston.

- 1028H54 piston/cylinder liner - r r, operation to be carried out on the entire set of pistons.

1.8 16v

Fit the piston rings using the tool.

Assemble the connecting rods with the 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.

2.4 20v

Fit the piston rings using the 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.

1.9 JTD 8v

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.

1.9 JTD 16v

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.

1.9 JTD 8v

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 explosion chamber (1b) in the piston.

Fit the pins and secure them using the circlips.

1.9 JTD 16v

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.