When assembling the piston and connecting rod, observe the following recommendations:
Fig. 130. Marking the piston bottoms before removing them
- arrow on the piston bottom (either drawn or stamped if the piston is new) should point towards the front of the engine (Fig. 130);
Fig. 56. Connecting rod and connecting rod bearing cap assembly. Arrows indicate protrusions
- the cast projections on the connecting rod and connecting rod cap (Fig. 56) must point in the direction of the engine crankshaft sprocket;
Fig. 55. Marking of the connecting rod and connecting rod bearing cap
- the cylinder number marking (Fig. 55) must be the same for the connecting rod and connecting rod cap.
Assemble the pistons and connecting rods in the following order:
- heat the piston to 60°C (to do this, put it in hot water) and select a mandrel that should fit inside the piston pin;
- heat the connecting rod;
Fig. 133. Installing the piston pin using a mandrel
- insert the piston pin into the heated piston and connecting rod by hand using a mandrel (Fig. 133). If the piston is very hot, you can wrap it in a rag;
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Fig. 132. Parts of the connecting rod and piston group: 1 - piston rings; 2 - retaining ring; 3 - piston pin; 4 - piston; 5 - connecting rod; 6 - connecting rod mounting bolt; 7 - connecting rod bearing shell; 8 - cylinder block; 9 - connecting rod bearing cap; 10 - connecting rod nut; A - marks on the connecting rod and cover; B - position of cast projections
- install the spring retaining rings 2 (Fig. 132) on both sides of the piston pin 3 and make sure that they fit tightly in the grooves;
Fig. 65. Checking the ease of movement of the connecting rod
- check: the connecting rod moves freely back and forth after assembly (Fig. 65). It should move smoothly, no jamming should be felt;
Fig. 58. Removing the piston ring using a puller
- lubricate the piston grooves and piston rings with engine oil and install the piston rings into the grooves using special piston ring pliers (Fig. 58). If the ring has an "Oben" or "Top" mark, install the ring with the mark facing up (to the piston bottom). Compression piston rings are easy to mix up. For this reason, you should look at their cross-section before installing them;
Fig. 59. Removing the piston ring using metal strips
- if there are no special pliers for installing piston rings, you can use metal strips (Fig. 59). To do this, put the rings on the metal strips and bring them to the level of the piston grooves. Then, pull out the metal strips and install the piston rings in the grooves.
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