Piston or Con-Rod, Replace
Remove engine with transmission.
Remove cylinder head.
Remove oil pan.
| See corresponding operation. | |||
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| .P. C5936.tif | 9 | 7,5 | tiff;; |
Mark all con - rod caps for identification and remove.
| Push pistons with con-rods upwards out of cylinder block. | |||
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| .P. C5937.tif | 9 | 7,5 | tiff;; |
Make note of piston installation position.
| Arrow or notch on piston head must face forwards, oil spray hole to manifold side, and bead in con-rod must point backwards. | |||
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| .P. C5938.tif | 9 | 7,5 | tiff;; |
Piston Pin on 6 Cylinder Engine, Remove and Install
Press out piston pin using Remover of KM-337 and a suitable supporting base. Piston pin and piston can no longer be used.
Con -rods and pistons are individually supplied as replacement parts.
| For assembly, the small con - rod eye must be heated to 280° C/536 °F. Use a commercially available hot plate for this. | |||
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| .P. D7320.tif | 9 | 7,5 | tiff;; |
If a hot plate is used, the necessary temperature use should be measured with thermocolour pencils. They are available under the designation "Thermochrom Pencils No. 2815/280" in stationery businesses which supply the Faber brand.
With the thermocolour pencil apply colour to piston pin eye as well as to the upper part of the con - rod stem and place con - rod with upper eye on hot plate.
In order to achieve a quick, even flow of heat, it is important that whole of eye surface lies completely flat on hot plate.
This requires a base support which is suited to height of hot plate.
To avoid loss of heat and in order to achieve a reduced pre -heat time, it is recommended that the eye be laid on a fireproof brick.
After heating the con -rod eye to 280° C/536° F the originally applied colour turns to black and shows the desired assembly temperature. Note that the colour cast mark should change as far as beginning of con -rod stem and not over the whole length (arrow).
Select new piston according to Table "Cylinder Grinding and Piston Dimensions".
| When the stamped size mark is not completely legible on the pistons measure piston diameter (see "Technical Data") from lower stem end (at right angles to piston pin axis) using a micrometer. | .P. C5940.tif | 9 | 7,5 | tiff;; |
After reaching assembly temperature tension con-rod slighty with protective jaws in vice. Place guide block and Remover/installer KM - 337 in piston pin (which has been coated with engine oil) and guide into bore of piston.
Guide piston over con - rod eye so that afore - mentioned installation characteristics are present and push piston pin up to stop of installer as far as piston in con -rod.
Piston pin must be installed quickly in order to prevent pin rapidly cooling and sticking, thus ending installation.
| A firmly seated piston pin cannot be pushed in further without risking deformation of the piston. | |||
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| .P. D7321.tif | 9 | 7,5 | tiff;; |
Piston Pin on 4 Cylinder Engine, Remove and Install
Remove snap rings from piston eye.
Push piston pin out of piston.
| When assembling, note correct installation position. | |||
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| .P. C8002.tif | 9 | 7,5 | tiff;; |
Mount piston rings, see corresponding operation.
Turn all con - rod journals to BDC or TDC position before inserting piston in cylinder.
Insert piston con -rod assembly with con -rod bearing shell halves in cylinder.
Note piston installation position.
Arrow (1) or notch on piston head must point forwards, oil spray hole to manifold side, and con - rod bead backwards.
Position piston ring tensioner and compress piston rings.
| Push piston into cylinder using hammer handle until con - rod bearing shell sits on con - rod journal of crankshaft. | |||
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| .P. D7322.tif | 9 | 7,5 | tiff;; |
Oil all con - rod bearings and mount bearing cover according to identification.
| Tighten down bearing cover to 45 Nm/32.5 lbf. ft. | |||
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| .P. C5943.tif | 9 | 7,5 | tiff;; |