Removing
Piston installation details
1. Remove the engine.
2. Remove the cylinder head.
3. Remove the pallet.
4. Remove the oil pump.
5. Remove the connecting rod caps (1).
6. Raise the crank (2) up with the piston (4). If the piston is damaged, the arrow indicating the direction of travel may not be visible due to soot. Therefore, it is necessary to remove carbon deposits.
7. Using a screwdriver, press out the retaining ring (5) piston pin (6) and remove the piston (4).
Installation
1. Check the inner diameters of the connecting rod heads.
2. Lubricate the piston pin with oil (4) connecting rod top bushings.
3. Align the piston (4) and connecting rod (2).
4. Press in the piston pin (6) by hand.
5. Insert retaining ring (5) piston pin into groove (arrow) in the piston.
6. Lubricate the cylinder bores, connecting rod journals, liners and pistons with oil (4).
7. Install the tension band (7) for piston rings.
8. Install the piston (4) arrow in the direction of travel.
9. Check connecting rod bolts.
10. Install connecting rod caps (1) and tighten the bolts.
11. Rotate the crankshaft and check the clearances.
12. Install the oil pump.
13. Install the pallet.
14. Measure piston protrusion. Install a nominal thickness shim or repair thickness shim depending on the piston protrusion.
15. Piston protrusion:
- On a new cylinder block - 0.74-0.96 mm
- On a polished cylinder block - 0.96-1.16 mm
16. Install the cylinder head.
17. Install the engine.