Removal
1. To disassemble and reassemble the piston and connecting rod, use special tools 09234–33001.
2. Install the universal supports into the clamp between the connecting rod and the piston.
3. Insert the puller through the hole in the clamp arch.
Warning! Insert the clamp with the piston, connecting rod and puller under the press slide.
4. Use a puller to push the piston pin out of the piston.
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Examination
Piston and piston pin
1. Inspect the outside surface of the piston for damage, wear, or uneven wear. Replace the piston if necessary.
2. Check each piston ring for damage and uneven wear. Replace piston rings if necessary.
3. Check the piston pin by inserting it into the piston hole. The piston pin should enter the piston smoothly when pressed by hand (at room temperature).
Piston rings
1. Insert a new piston ring into the piston groove and use a feeler gauge to measure the gap between the piston ring and the groove wall. If the gap exceeds the maximum permissible value, replace the piston.
Clearance between piston ring and piston groove:
- First compression ring: 0.04–0.085 mm
- Second compression ring: 0.04–0.085 mm
- Maximum permissible gap: 0.1 mm
2. Measure the piston ring gap by manually inserting the piston ring into the engine cylinder. Use the piston crown to push the piston ring into the bottom of the cylinder. Use a feeler gauge to measure the piston ring gap.
Piston ring gap:
- First compression ring: 0.15–0.30 mm
- Second compression ring: 0.20–0.40 mm
- Oil scraper ring: 0.20-0.70 mm
- Maximum clearance: 1.0 mm
Installation
1. Install the spacer sleeve.
2. Install the upper side guide. To install the side guide, first place one end of the side guide between the piston ring groove wall and the spacer sleeve, press it down, then press it around the perimeter to install it into the piston groove.
Warning: Do not use pliers to spread the piston rings when installing the side guide.
3. Install the low side guide in the same manner.
4. Using piston ring pliers, install compression ring No.2.
5. Using piston ring pliers, install compression ring No.1.
6. Apply a thin layer of motor oil to the piston and piston rings.
7. Position the piston ring locks as shown in the figure.
8. Using a special tool, compress the piston rings onto the piston.
9. Install the guide pins through the piston into the connecting rod and install the piston pin on the other side of the piston.
Warning! The guide pins determine the position of the connecting rod in the piston. After installing the piston, connecting rod, piston pin and piston pin installation tool into the inserts, the guide pins also determine their position in the clamp.
10. Install the piston assembly onto the clamp, with the guide pin supporting the connecting rod in the piston pin.
11. Check the correct relative position of the piston and connecting rod and, by turning the knurled nut, secure the numbered sleeve on the shaft.
12. Insert the shaft through the hole in the clamp arch. Press the piston pin into the connecting rod until the bushing on the shaft contacts the top of the clamp arch, and the guide pin should fall out of the piston.
Warning! The piston pin pressing force must not exceed 22,500 N.
Pressing depth: 0.3–0.5 mm