Install
Important. If a piston has a pressed-in con-rod and replacement of one of the two parts is necessary, all components of the assembly (piston, piston ring, piston pin and con-rod) must be replaced with new parts. From engine number 19P13554, reinforced con-rods shall be used in conjunction with modified con-rod bolts (M6.5). Make sure that the new con-rod bolts are only used with the modified con-rods.
- 1. Tightening torques: I: Tightening torque, M6 bolt: 10 Nm + 60° + 15° II: Tightening torque, M6.5 bolt: 13 Nm + 60° + 15°
- 2. Assemble guide drift from KM-634-6 (1), KM-634-7 (2) and KM-634-5 (3)
- 3. Insert new piston • in cotter groove of KM-634-1 (1)
Note. Piston pin bore must be in horizontal position
- 4. Install KM-634-4 (3) • To KM-634-1
Note. Only tighten fastening bolts hand-tight
- 5. Clamp piston so it cannot be rotated • with KM-634-2 (2)
- 6. Determine piston pin offset • Slide assembly (1) comprising KM-634-6 , KM-634-7 (same length as piston pin) and KM-634-5 through piston pin bore and con-rod – until KM-634-7 is centred in piston • In this position, KM-634-4 (2) must abut (no gaps) the tip of the assembly (arrows) • Tighten fastening bolts of KM-634-4
- 7. Insert piston pin • Remove KM-634-7 from guide drift and replace with new piston pin – Lubricate piston pin with oil
- 8. Heat con-rod • Heat new con-rod at upper con-rod eye using heating plate – Assembly temperature: 280°C to 320°C – Lay eye surface flat on heating plate – Reduce heat dissipation by using flameproof firebrick
- 9. Piston and con-rod installation position • Bead (1) on con-rod is opposite arrow on piston head • Arrow on piston head points toward engine timing side • Bead on con-rod is on transmission side
- 10. Assemble piston and con-rod • Slide assembly of KM-634-6 , piston pin and KM-634-5 through piston pin bore and con-rod – evenly and without delay – until it abuts (no gaps) KM-634-4
Remove
- 11. Remove KM-634-5 and KM-634-6 • right and left from piston pin