Piston with connecting rod - r r

Operation 1028H20 · Pistons and connecting rods

1.2 16v

Removing

Place the car on a ramp.

- 1048A10 air cleaner filtering element - replace

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1072C16 exhaust manifold with catalytic converter - r r

- 1008B10 power unit front mount (timing side) flexible block - replace

- 1008A46 cam shaft left rigid mount - r r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 1032D12 timing system protective cover(s) - r + r

- 1092B60 alternator drive belt - r + r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1016B10 single cylinder head extension - change gasket

- 1016C10 cylinder head - r + r and replace gasket

- 1020A30 engine oil drain plug - replace

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

1. Undo the bolts fixing the connecting rod cap.

1.4 16v

Removing

Place the car on a lift.

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

- 4450B04 right front wheel r r

- 7055B54 under-engine guard - r r

- 1048A10 air cleaner filtering element - replace

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1072C16 exhaust manifold with catalytic converter - r r

- 1008B10 power unit front mount (timing side) flexible block - replace

- 1008A46 cam shaft left rigid mount - r r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 1032D12 timing system protective cover(s) - r + r

- 1092B60 alternator drive belt - r + r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1056B60 single fuel manifold pipe, with injectors - r + r

- 1016B10 single cylinder head extension - change gasket

- 1016C10 cylinder head - r + r and replace gasket

- 1020A30 engine oil drain plug - replace

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

1. Undo the bolts fixing the connecting rod cap.

1.6 16v

Refer to op. 1028H10 connecting rod and piston set - r r

1.8 16v

Refer to op. 1028H11 piston connecting rod set - r r

2.4 20v

Removing

- 7055B54 under-engine guard - r r.

- 1016A40 ignition coil cover on cylinder head- r+r

- 5530B56 BATTERY DRIP TRAY COVER - R.R.

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

- 1056B82 injection/ignition system e.c.u. (one) - r + r

- 1056B14 throttle case - r + r

- 1072B10 inlet manifold - r + r and replace seal

- 1072D50 device (vis) with adjustable air ducts - r r

- 1088E10 radiator cooling fan - r + r

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1072C10 exhaust manifold - r + r and replace seal

- 4450B04 right front wheel r r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 1092D10 air conditioner compressor drive belt - r + r

- 1092B68 belt from a/c compressor to alternator drive r + r

- 1092A10 Crankshaft services PULLEY - R.R.

- 1016C10 cylinder head - r + r and replace gasket

- 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

1. Undo bolts (1a) and remove big end bearing cap (1b). then remove big end half-bearing (1c).

1.9 JTD 8v

This operation should be carried out with the engine at the bench. After having remove the power unit, separate the gearbox - differential unit from the engine and position the latter on the rotating stand for overhauling.

Remove the pistons, referring to the operations illustrated in the manual for overhauling this engine at the bench.

1.9 JTD 16v

This operation should be carried out with the engine at the bench. After having remove the power unit, separate the gearbox - differential unit from the engine and position the latter on the rotating stand for overhauling.

Remove the pistons, referring to the operations illustrated in the manual for overhauling this engine at the bench.

1.2 16v

Lower the lift.

Remove the piston complete with connecting rod.

1.4 16v

Lower the ramp.

Remove the piston complete with connecting rod.

2.4 20v

Lower the vehicle.

Remove the connecting rod with the piston.

Remove the big end bearing shell.

1.2 16v

Refitting

1. Use the tool (1a) and fit the piston (1b) in the cylinder liner/bore.

Make sure that the arrow, stamped on the piston crown, is facing the timing side and that the number, stamped on the big end, corresponds to the one of the connecting rod cap.

1.4 16v

Refitting

1. Use the tool (1a) and fit the piston (1b) in the cylinder liner/bore.

Make sure that the arrow, stamped on the piston crown, is facing the timing side and that the number, stamped on the big end, corresponds to the one of the connecting rod cap.

2.4 20v

Refitting

Fit the connecting rod and piston and the connecting rod half-bearings using a fitting tool.

Fit the connecting rod - piston assembly in the cylinder block/crankcase so that the number stamped on the small end is facing the inlet side.

Fit the big end half-bearing and tighten the cap bolts to torque.

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1076B70 exhaust pipe between pre-catalytic converter and catalytic converter - r r

- 1092A10 Crankshaft services PULLEY - R.R..

- 1092B68 belt from a/c compressor to alternator drive r + r

- 1092D10 air conditioner compressor drive belt - r + r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 4450B04 right front wheel r r

- 1072C10 exhaust manifold - r + r and replace seal

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1088E10 radiator cooling fan - r + r

- 1072D50 device (vis) with adjustable air ducts - r r

- 1072B10 inlet manifold - r + r and replace seal

- 1056B14 throttle case - r + r

- 1056B82 injection/ignition system e.c.u. (one) - r + r

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

- 5530B56 BATTERY DRIP TRAY COVER - R.R.

- 1016A40 ignition coil cover on cylinder head- r+r

- 0010T21 coolant check density and top up if necessary

- 0010T20 coolant change

- 0010T40 change manual gearbox oil.

- 0010T41 MANUAL GEARBOX OIL - Check level and top up, if necessary.

1.2 16v

Position the connecting rod caps and secure them tightening the bolts to the recommended torque.

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1020A30 engine oil drain plug - replace

- 1016C10 cylinder head - r + r and replace gasket

- 1016B10 single cylinder head extension - change gasket

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1092A10 Crankshaft services PULLEY - R.R.

- 1092B60 alternator drive belt - r + r

- 1092B64 alternator drive belt - adjust tension

- 1032D12 timing system protective cover(s) - r + r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 1008A46 cam shaft left rigid mount - r r

- 1008B10 power unit front mount (timing side) flexible block - replace

- 1072C16 exhaust manifold with catalytic converter - r r

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1048A10 air cleaner filtering element - replace

- 0010T10 change engine oil

- 0010T20 coolant change

Remove the vehicle from the ramp.

1.4 16v

Position the connecting rod caps and secure them tightening the bolts to the recommended torque.

- 1084B28 engine oil intake pump - r + r with crankcase sump removed

- 1020A20 crank case oil sump - r + r clean seals for sealant application

- 1020A30 engine oil drain plug - replace

- 1016C10 cylinder head - r + r and replace gasket

- 1016B10 single cylinder head extension - change gasket

- 1056B60 single fuel manifold pipe, with injectors - r + r

- 1032B10 toothed timing belt - r + r for timing adjustment or replacement

- 1092A10 Crankshaft services PULLEY - R.R.

- 1092B60 alternator drive belt - r + r

- 1092B64 alternator drive belt - adjust tension

- 1032D12 timing system protective cover(s) - r + r

- 7055B42 Additional FRONT WHEEL ARCH (one), left or right - R.R.

- 1008A46 cam shaft left rigid mount - r r

- 1008B10 power unit front mount (timing side) flexible block - replace

- 1072C16 exhaust manifold with catalytic converter - r r

- 1072C44 exhaust manifold heat shield on bulkhead - r+r

- 1048A10 air cleaner filtering element - replace

- 0010T10 change engine oil

- 0010T20 coolant change

- 7055B54 under-engine guard - r r

- 4450B04 right front wheel r r

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

Remove the vehicle from the lift.