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The pistons and connecting rods
Withdrawal Cover rod |  | Keep the covers of rods with respective connecting rods for proper re-installation of the engine cylinders. |
 | 1. Remove 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. |
2. The block of wood or hammer handle push the piston rod of the cylinder.
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Removing and installing piston pin |  | 1. For the disassembly and reassembly of the piston and the connecting rod is necessary to use special tools 09234-33001. |
2. Set the universal support in the nip between the connecting rod and the piston.  | 3. Insert the removal tool through the hole in the arch of the clamp.  | Insert the clamp with piston rod puller and a press ram. |
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4. A stripper squeeze out the piston pin from the piston.  | 5. Install the 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. |
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6. Install the piston assembly to the clamp, and the guide pin support rod in the 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.  | 8. Insert the shaft through the hole 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 must not exceed 2450-12255 N. |
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Check The piston and piston pins | 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). |
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Piston rings | 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: 0.04-0.08 mm
- The second compression ring: 0,03-0,07 mm
- Maximum permissible backlash: 0,1 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: 0.20-0.35 mm
- The second compression ring: 0,37-0,52 mm
- Scraper ring: 0,30-0,90 mm
- Maximum permissible backlash: 1,0 mm
- The first and second compression rings: 0.8 mm
- Scraper ring: 1.0 mm
When replacing the piston ring without cylinder bore, check the clearance in the lock ring by placing it in the lower part of the cylinder. As the parts are supplied piston rings increased in size by 0.25, 0.50, 0.75 and 1.00 mm. | Markings applied to the piston ring on the top side of the ring near its lock. |
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Cranks |  | 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. |
2. 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. |
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Setting |  | 1. Install the expansion ring. |
 | 2. 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. | Do not use pliers for a release of piston rings when installing side rail. |
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3. Likewise, set the lower side rail.
4. Lubricate pistons and piston rings with engine oil.
5. 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. |
 | 7. Place the piston rings, as shown in the figure. |
8. The special adaptation compress piston rings on the piston.
9. Install the upper main bearing shells in the crankcase.  | 10. Install connecting rod bearings into the connecting rod cap. | Inserts with a groove for lubrication to be installed in the cylinder block. |
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 | 11. Establish persistent half rings in the main bearing cap ?��3, lubrication grooves outward. |
12. Establish the piston with the piston rings over the first cylinder, and the mark on the piston must be pointing toward the front of the cylinder.
13. hammer handle press the piston into the cylinder so that the bottom head of a rod was established on the crankshaft. | | 14. Install the connecting rod cap. Make sure that the label on the cylinder rod and connecting rod cap are on one side. |
15. Screw bolts as follows. - Apply engine oil to the contact area and thread nuts.
- Tighten the bolt of the connecting rod cap.
Torque: 16-20 N ??? m + to tighten on a corner 90 ?� -94 ?�  | 16. Check the play in the bearings as follows: - Clean bearings and indigenous and crank pins of grease and lubrication holes blow compressed air.
- Arrange pieces of plastic measuring rod Plastigauge on the necks of the crankshaft bearing.
- In accordance with the markings set bearing caps. In certain sequence tighten bolts of covers of bearings of the crankshaft. Do not turn the crankshaft when measuring the gap crankshaft bearings.
- Remove the bolts and remove the crankshaft bearing caps of the crankshaft. The measuring template measure width of deformed plastic core Plastigauge and define backlash size.
Clearance crankshaft bearing: 0,018-0,036 mm
Maximum permissible backlash crankshaft bearing: 0.1 mm |
 | 17. A 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 |
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