Piston

1. Unscrew the nuts and remove the connecting rod cap and the lower connecting rod bearing liner. To protect the crankshaft journals put on bolts of covers of rods pieces of a rubber or plastic tube.

Pieces of wood or hammer handle push the piston rod of the cylinder.

For disassembly and reassembly of the piston and the connecting rod is necessary to use special tools 09234-33001 and 09234-33002.

2. Set the universal support in the nip between the connecting rod and the piston.

Insert puller through a hole in the clamp arch.

Insert the clamp with piston rod puller and a press ram.

4. A stripper squeeze out the piston pin from the piston.

Install guide pins through the piston to the connecting rod and piston pin set on the other side of the piston.

The guide pins define the position of the connecting rod in the piston. After you install the piston, connecting rod, piston pin, and for adjustment of the piston pin during insertion, guide pins also determine their position in the clip. If guide pins are too small, the piston is not centered in the device and the clip can be damaged and / or device.

6. Set the piston assembly to the clamp, wherein guide pin supports connecting rod piston pin. Make sure that the plunger is pushed over the clamp until the guide pin engages with a fork insertion.
7. Check that the mutual position of the piston and connecting rod and turn the knurled nut, attach numbered sleeve on the shaft.

Insert the shaft through an opening in the arch of the clip. Push piston pin to connecting rod, while the sleeve on the shaft engages with the upper part of the clamp arch, wherein the guide pin has to fall from the piston.

The force pressing the piston pin should not exceed 350-1350 kg on engines of 1.8 and 2.0 liters and 1,250 ?� 500 kg per 1.6 liter engine.

1. Check the outer surface of the piston for damage, develop or uneven wear. If necessary, replace the piston.
2. Check each piston ring for damage and uneven wear. If necessary, replace the piston rings. When replacing the piston as the piston rings must be replaced.
3. Check the piston pin by inserting it into the hole of the piston. The piston pin must be a smooth entrance into the piston by pressing it by hand (at room temperature).

1. Insert the new piston ring in the groove of the piston and probe measure the clearance between the piston ring and the wall of the groove. If the clearance exceeds the limit, replace the piston.

The gap between the piston ring and the groove in the piston:

The first compression ring:

- Engines of 1.8 and 2.0 liters: 0.04-0.08 mm;
- Engines of 1.6 liters: 0,04-0,085 mm.

The second compression ring:

- Engines of 1.8 and 2.0 l: 0,03-0,07 mm;
- Engines of 1.6 liters: 0,04-0,085 mm.

2. Measure the end gap of the piston rings, piston ring is manually inserted into the engine cylinder. Piston crown push the piston ring into the bottom of the cylinder. Feeler gauge, measure the end gap of the piston ring.

The gap piston ring:

The first compression ring:

- Engines of 1.8 and 2.0 l: 0,23-0,38 mm;
- Engines of 1.6 liters: 0.15-0.30 mm.

The second compression ring:

- Engines of 1.8 and 2.0 l: 0,33-0,48 mm;
- Engines of 1,6 l: 0,30-0,45 mm.

Scraper ring:

- Engines of 1.8 and 2.0 l: 0,20-0,60 mm;
- Engines of 1,6 l: 0,20-0,70 mm.

Maximum permissible backlash:

The first and second compression rings: 1.0 mm.
Scraper ring: 1.0 mm.

Markings applied to the upper portion of the piston ring on the lock side.

1. When installing, make sure that the connecting rod and connecting rod cap correspond to the number of the cylinder in which they are established. When installing a new rod, make sure that the labels defining its position, located on the same side as the label on the remaining rods.

Replace the connecting rod, if there is damage on both bearing surfaces. Also replace the rod, if any wear or damage to the surface mating with piston pin.

Check code size diameter of the cylinder located on the front side of the cylinder block.

Check code size diameter piston disposed on the piston crown.

The code size of the diameter of the piston is stamped on the piston crown.

3. Select the piston, the diameter of which corresponds to the class of the cylinder. The clearance between the piston and the cylinder: 0,025 - 0,045 mm.

	Install the expansion ring.
	Install the upper side rail. To install the side rail, first place one end of the side guide wall between the piston ring groove and the expansion ring, press it, and then clicking on the perimeter, install it in the groove of the piston.
	Likewise, set the lower side rail.

Do not use pliers for a release of piston rings when installing side rail.

4. Apply a thin coat of engine oil to the piston and piston rings.

Pliers for a release of piston rings, set the compression ring ?��2.

6. Pliers for a release of piston rings, set the compression ring ?��1.

Place the piston rings, as shown in the figure.

8. The special adaptation compress piston rings on the piston. Establish the piston with the piston rings on the first cylinder, wherein the groove on the piston to be directed towards the front of the cylinder block. Hammer handle press the piston into the cylinder so that the bottom head of a rod was established on the crankshaft.
9. Install the upper main bearing shells on the engine block. When reinstalling the inserts install them on the same places where they were before removal.
10. Install main bearing shells in main bearing caps of the crankshaft.
11. Make sure that the label on the piston rod and directed towards the front of the cylinder block.
12. When installing a new rod, make sure that the recesses for the bearing are located on one side.
13. Tighten bolts and nuts of fastening of covers of rods.
1. engine oil to lubricate the threads of nuts and bolts;
Torque tighten the bolts and nuts of covers of rods.

Torque:

- Engines of 1.8 and 2.0 x 50-53 N ??? m;
- Engines of 1,6 l: 32-35 N ??? m.

Do not use more than three times the bolts of covers of rods.

14. Probe inserted between the connecting rod and the crankshaft, connecting rod, measure the backlash. Nominal backlash rod: 0.10-0.25 mm. Maximum permissible backlash: 0,40 mm
15. Install the oil filter.
16. Install the oil pan.
17. Install the cylinder head.