37
Piston and connecting rod
7
Remove the big end bearing cap and the connecting
rod bearing caps, operation 13A-01. Keep the bear-
ing shells with the relevant caps so that they can be
returned to their original positions.
8
Install rubber or plastic protective tubes on the con-
necting rod screws (B1). Slide the piston and the
connecting rod upwards in the cylinder bore A suita-
ble tool for this job can be made from a (U) shaped
pipe and two pieces of plastic hose (C).
9
Check the big end journal for damage.
10
Ensure that the piston, cylinder bore, big end jour-
nal and connecting rod big end are clean. Lubricate
the piston and cylinder bore with fresh engine oil.
11
Turn the crankshaft until the relevant connecting rod
is in its lowest position. Lubricate the big end jour-
nal with engine oil.
12
Install a plastic or rubber tube of suitable length on
each respective connecting rod screw to protect the
big end. Install the upper bearing shell on the con-
necting rod. Ensure that the locking lug is slid well
into the cut out (A1). Lubricate the bearing with en-
gine oil.
13
Ensure that the piston ring gaps are offset by 120°
and press the rings together with a piston ring com-
pressor (D1). Ensure that the protruberances
pressed against one edge of the tool are bent down-
wards.
14
Install the piston unit in the correct cylinder bore.
When the piston is installed the arrow on the upper
side of the piston (D) must point towards the front
end of the engine (timing cover end). In this position
the combustion chamber on the top of the piston is
turned towards the side of the engine on which the
injection pump is installed. There is also a front end
marking on the underside and on the connecting rod
and these markings must be on the same side, see
13A.07/B.
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