Withdrawal
Connecting rod cap
Note. Keep the bushings in order according to the numbering of the connecting rods (according to cylinder numbering), for later installation.
1. Turn away a nut of a cover of the lower head of a rod and remove a cover and the bottom loose leaf.
2. Slide each connecting rod to the top of the cylinder.
The procedure for removing and installing the piston pin
1. Use special tools (09234-32001) for disassembly and assembly of the piston and connecting rod.
2. Install the appropriate insert in the fork of the tool. Position the insert between the connecting rod and piston.
3. Insert the puller into the hole in the tool arch.
4. Press the piston pin out of the top end of the connecting rod.
5. Enter the guide pin through the piston into the upper head of the connecting rod. Enter the guide pin from the opposite side of the piston.
6. Install the piston assembly in the fork of the device. The device will support the connecting rod on the piston pin. Push the piston into the fork until the guide pin stops against the insert.
7. Adjust the setting rod to the appropriate length by turning the numbered bushing on the lettered shaft until the alphanumeric value specified in the application diagram is obtained. Turn the socket nut to lock the sleeve with numbers on the shaft.
8. Insert the setting rod into the hole in the arch of the device. Press the piston pin into the connecting rod head until the rod bushing touches the top of the arc of the device. The guide pin will fall out of the connecting rod head when the piston pin is pressed in.
Examination
Piston and piston pin
1. Check each piston for galling, scuffing, wear and other defects. Replace any defective pistons.
2. Check each piston ring for damage or excessive wear. Replace defective rings.
3. Check the fit of the piston pin in the piston boss holes. Replace all defective pistons and piston pins. The piston pin should slide smoothly into the piston boss holes by hand at room temperature.
Piston rings
1. Check the side clearance of the piston rings. If the measured value exceeds the allowable value, insert a new ring into the piston groove and measure the backlash. If the gap again exceeds the allowable value, replace the piston and piston rings.
Piston ring side clearance
Rated value:
- No. 1 - 0.04-0.085 mm
- No. 2 - 0.04-0.085 mm
Limit value:
- No. 1 - 0.1 mm
- No. 2 - 0.1mm
2. For measurement of a backlash in the lock of a piston ring enter rings into the cylinder. Install the ring in a plane perpendicular to the cylinder wall by slightly pushing the piston on the ring. Measure the gap with a feeler gauge. If the clearance is out of tolerance, replace the piston ring.
Connecting rods
1. When installing the connecting rod cap, make sure that the cylinder numbers printed on the connecting rod and cap match. When installing a new connecting rod, make sure the bushing retaining cutouts are on one side.
2. Replace the connecting rod if there is damage to the pressure-receiving surfaces of the upper and lower heads, and if there is stepped wear or if the inner surface of the upper head bore is very rough.
3. Using a connecting rod alignment tool, check the connecting rod shaft for bending and twisting. If the measured value is close to the limit, correct the connecting rod with a press. Any bent or deformed connecting rod should be replaced.
Allowable crank bend 0.05mm/100mm or less
Allowable crank twist is 0.1mm/100mm or less
Installation
1. Install spacer ring.
2. Install the top side ring. To install it, insert one end of it between the wall of the piston ring groove and the spacer ring, press it to the bottom of the groove and, pressing with your finger, as shown in the figure, insert the upper side ring into the groove.
Note: Do not use a piston ring expander when installing the side rings.
3. Install the bottom side ring in the same way.
4. Using a piston ring expander, install piston ring #2.
5. Install piston ring #1.
6. Apply engine oil to the outer surfaces of the piston and piston rings.
7. Position the piston rings so that the gaps in the locks of adjacent piston rings are as far apart as possible. Make sure these gaps are not in the directions of the piston pin axis and load bearing.
8. When installing the piston in the cylinder, press the rings into the grooves of the piston using a swage.
9. Make sure that the mark marking the front of the piston and the mark marking the front of the connecting rod (identification label), are directed towards the front of the engine.
10. When installing the cap of the lower head of the connecting rod, make sure that the marks corresponding to the cylinder number on the connecting rod and the cover match.
11. When installing a new connecting rod, make sure that the cutouts for holding the liners are located on one side.
12. Tighten nuts of fastening of a cover of the bottom head of a rod.
Tightening torque: Connecting rod cap nuts 35-38 Nm (350-380 kg/cm).
13. Check up a backlash of a rod.
- Side clearance - 0.10-0.25 mm
- Limit value - 0.4 mm