Withdrawal
Connecting rod cap
Attention! Keep the connecting rod caps with the appropriate connecting rods for proper reinstallation in the engine cylinders.
1. Turn away nuts and remove a cover of a rod and the bottom loose leaf of a rod bearing. For protection of necks of a cranked shaft put on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
2. Use a block of wood or a hammer handle to push the piston and connecting rod out of the cylinder.
Removal and installation of a piston pin
1. Disassembly and assembly of pistons with connecting rods is carried out using tools 09234-33001 and 09234-3302.
2. The piston pin is pressed into the upper head of the connecting rod and rotates freely in the piston bosses.
3. The tool consists of a clevis with fork inserts, guide pins, adapters, a puller for pressing out and a tool for installing a piston pin. When pressing out and pressing in the pin, the piston is mounted on the clamp. The guide pins provide the desired pin position, and the inserts support the crank.
4. To press out the pin, place the piston in the clamp so that the connecting rod rests on the forked inserts. Insert a puller into the hole in the top of the clamp and press out the piston pin.
5. To press the pin, install the appropriate fork inserts on the clamp to support the connecting rod.
6. Insert the connecting rod into the piston. Insert an appropriate guide mandrel into the piston boss and connecting rod bore. With light strokes by hand, move the guide pin so that it fits into the other piston boss. Insert a new piston pin into the piston boss from the side opposite the pilot pin and install the piston with connecting rod on the clamp support with the pilot pin down.
Note. The guide pins determine the position of the connecting rod in the piston. When properly assembled, the drive pin should be exactly under the center of the hole in the fixture bracket and rest evenly on the fork inserts. If a pilot pin of the wrong diameter is used, the piston and pin will not align with the support.
7. Insert the press tool through the hole in the arch of the clamp. Press the piston pin into the connecting rod until the sleeve on the shaft contacts the top of the arch of the clamp, and the pilot pin should fall out of the piston.
Attention! At the moment when the pressing device reaches the stop against the clamping arch, the pressing force should not exceed 1250±500 kgf.
Examination
Piston and piston pins
1. Check the outer surface of the piston for damage, wear, or uneven wear. If necessary, replace the piston.
2. Check each piston ring for damage and uneven wear. If necessary, replace piston rings. When replacing a piston, the piston rings must also be replaced.
3. Check the piston pin by inserting it into the piston bore. The piston pin should smoothly enter the piston 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 clearance exceeds the maximum allowable value, replace the piston and rings. If the gap does not exceed the maximum permissible value, replace only the piston rings.
Clearance between the piston ring and the groove in the piston, mm:
- top compression ring: 0.04–0.085
- lower compression ring: 0.04–0.085
Maximum allowable 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 clearance in the piston ring lock. If the gap exceeds the maximum allowable value, replace the ring.
Clearance in piston ring locks, mm:
- First compression ring: 0.20–0.35
- Second compression ring: 0.37–0.52
- Oil scraper ring: 0.2–0.7
- Maximum allowable gap: 1.0 mm
When replacing rings without boring the cylinders, the lock gap can be checked by installing the rings in the lower, less worn part of the cylinder.
Note. The marking is applied to the upper part of the piston ring, from the side of the lock.
Connecting rods
1. When installing, make sure the connecting rod and connecting rod cap match the cylinder number they are installed in. When installing a new connecting rod, make sure that the marks that determine its position are on the same side as the marks on the other connecting rods.
2. Replace the connecting rod if there is damage on both bearing surfaces. Also replace the connecting rod if there is wear or damage to the piston pin mating surface.
Pistons selection
1. Check the cylinder bore size code located on the face of the cylinder block.
3. Select a piston whose diameter matches the cylinder class. Gap between piston and cylinder, mm:
- 1.6L engine: 0.025–0.045
- 1.5L engine: 0.020–0.040
Installation
1. Install the oil ring expander.
2. Install the top side rail of the oil scraper. To install the side guide, first place one end of the side guide between the wall of the piston ring groove and the expansion ring, push it in, then press it all the way into the piston groove.
Note. Do not use piston ring pliers when installing the oil ring side guide.
3. Install the oil scraper ring lower side guide in the same manner.
4. Apply a thin layer of engine oil to the piston and piston rings.
5. Using pliers to expand the piston rings, install the lower compression ring.
8. Use the special tool to compress the piston rings on the piston. Install the piston with piston rings over the first cylinder.
Using a hammer handle, press the piston into the cylinder so that the lower end of the connecting rod rests on the crankshaft journal.
9. Establish the top loose leaves of radical bearings on the block of cylinders of the engine. When reinstalling the earbuds, install them in the same places they were before removal.
10. Install the main bearing shells in the crankshaft main bearing caps.
11. Be convinced that marks on the piston and a rod are directed to a forward part of the block of cylinders.
12. When installing a new connecting rod, make sure that the grooves for the bearing shell are on one side.
13. Tighten bolts and nuts of fastening of covers of rods.
- 1) Lubricate the threads of the nuts and bolts and the contact areas with engine oil.
- 2) Torque tighten the connecting rod cap bolts and nuts.
Tightening torque: 32–35 Nm
Warning! Do not reuse the connecting rod cap bolts more than three times.
14. With a feeler gauge inserted between the connecting rod and the crankshaft, measure the side clearance of the connecting rod.
- Rated connecting rod side clearance: 0.10mm
- Maximum allowable gap: 0.40 mm
15. Install the oil strainer.
16. Install the oil pan.
17. Install the cylinder head.