Withdrawal
1. Special tools 09234-33001 must be used to disassemble and reassemble the piston and connecting rod.
2. Install universal supports in the clamp between the connecting rod and piston.
3. Insert the puller through the hole in the arch of the clamp.
Note. Insert the clamp with the piston, connecting rod and puller under the press slider.
4. With a puller, press the piston pin out of the piston.
Installation
1. Install the guide pin through the piston into the connecting rod. 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 guide pin.
Note.
- The guide pins determine the position of the connecting rod in the piston. Once the piston, connecting rod, piston pin and piston pin installer are installed prior to insertion, the guide pins also determine their position in the clamp.
- If a pilot pin of the wrong diameter is used, the piston will not be centered in the tool, which may cause damage to the universal support yoke and/or tool inserts.
2. Install the piston assembly on the support yoke with the guide pin supporting the connecting rod in the piston pin.
3. Adjust the length of the press tool by rotating its digitized sleeve relative to the letter-marked stud until an alphanumeric designation of the length indicated in the operation card is obtained, then fix the digitized sleeve on the stud by rotation, knurled nuts.
4. Insert the installation tool through the hole in the arch of the universal support. Press the piston pin into the connecting rod until the sleeve on the shaft contacts the top of the support arch, and the guide pin should drop out of the piston.
Attention! The piston pin pressing force must not exceed 22680 N.
Examination
Piston and piston pin
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.
If the gap does not exceed the maximum permissible value, replace only the piston rings.
Gap between piston ring and piston groove:
Top compression ring:
- 1.3L engine: 0.04–0.085 mm
- 1.1L engine: 0.03-0.07mm
Bottom compression ring:
- 1.3L engine: 0.04–0.085 mm
- 1.1L engine: 0.02-0.06mm
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.
Piston ring clearance:
First compression ring:
- 1.3L engine: 0.20–0.35 mm
- 1.1L engine: 0.15–0.30 mm
Second compression ring:
- 1.3L engine: 0.37–0.52 mm
- 1.1L engine: 0.30–0.50 mm
- Oil scraper ring: 0.20–0.70 mm
- 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.
Rings must be replaced with rings of the same size group. Dimensional groups of piston rings according to the gap in the lock and their marking.
Nominal: Unmarked 0.25mm: 25; 0.50 mm: 50; 0.75mm: 75; 1.0 mm: 100.
Note. The marking is applied on the top surface of the ring.
Pistons selection
1. Check the cylinder bore size code located on the top plane of the cylinder block (engine 1.3 l).
Check the cylinder bore size code located on the bottom mating surface of the cylinder block (engine 1.1 l).
2. Check the piston diameter size code located on the piston crown.
3. Select a piston whose diameter matches the cylinder class. Clearance between piston and cylinder: 0.02–0.04 mm.
Installation
1. Install the oil ring expander.
2. Install the oil scraper ring top side guide. 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 side guide.
3. Install the lower side rail in the same way.
4. Using pliers to expand the piston rings, install the lower compression ring.
5. Install the top compression ring.
6. Apply a thin layer of engine oil to the piston and piston rings.
7. Position the piston ring locks as shown.
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. Make sure that the marks on the pistons are directed towards the front of the cylinder block
10. At installation of covers of rods watch conformity of numbers put on rods and a cover at dismantling.
11. When installing a new connecting rod, make sure that the grooves for the bearing shell are on one side.
12. Tighten bolts and nuts of fastening of covers of rods.
Torque:
- 1.3L engines: 32–35 Nm
- 1.1L engines: 20–23 Nm
13. 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