Assembling and mounting of piston and connecting rod

1 Lubricate the gudgeon pin, and mount it from the same side from where it was removed, with the end marked with the drawing number in the same direction. The cylinder number is stamped on the piston crown and connecting rod, Fig 11-3.

When changing the piston, mark the new piston with the same cylinder number in the same place as on the replaced one.

At low temperatures, the gudgeon pin may stick but will be easily fitted after heating the piston to about 30°C, e.g. in oil.

2 Mount the securing ring (7).

Note! Never compress the securing ring more than necessary to fit into the groove. If the ring is loose in its groove after mounting, it must be replaced by a new one.

3 Take off the protecting tape from the crank pin oil holes and lubricate the crank pin with clean engine oil.

Always when mounting flute or/and the limiter is/are mounted in the crankcase observe extremely cautiousness when using the turning device.

4 Rotate the crankshaft by using the turning device manu-ally until the big end halves can be placed on the crank pin.

5 Mount the mounting flute through the crank case open-ings on the crankcase cover lower studs and tighten the nuts, see Fig 11-5.

Mounting tools for connecting rod

Note! The guiding pins between upper part of connecting rod and big end should be towards free end.

800017 Guiding plug 800018 Limiter for piston

800102

800098

800099 800018

800020

800017

55˚

800098 Mounting flute 800099 Supporting plate 800102 Mounting support 800020 Hydraulic tool

Fig 11-5 ^4011029601

6 Clean the big end upper half carefully. Lubricate the bearing surface and back side of the bearing shell with oil.

Mount the shell, so that the lug guides in its groove.

Note! It is very important that the bearing shells are mounted straight.

7 Lift the upper big end half with the sledge in the mount-ing flute.

8 Push the upper big end half carefully against the crank-shaft, take care not to damage the crank pin.

9 Clean the big end lower half carefully. Lubricate the bearing surface and back side of the bearing shell with oil.

Mount the shell, so that the lug guides in its groove.

Note! It is very important that the bearing shells are mounted straight.

10 Lift the big end lower half on the sledge.

11 Push the lower big end half carefully against the crankshaft and check that guiding pins are in right position, take care not to damage the crank pin.

12 Mount the nuts and tighten by hands.

13 Remove the sledge from operating side of the engine.

14 Remove the sledge from rear side of the engine by open-ing the nuts.

15 Mount the mounting support 800102 on the upper crank case stud, see Fig 11-5. Tighten the nut.

16 Remove the mounting flute and supporting plate by opening nuts.

17 Lift the hydraulic tools 800020 in to the position.

18 Connect the hoses of the hydraulic pump 800053 and proceed with tightening of the nuts in two steps as described in adjacent figure. Tightening torques see section 07.3.

Caution! The screws will be overloaded if the maximum hydraulic pressure is exceeded.

It is recommended to change the screws if maximum hydrau-lic pressure is exceeded for some reason.

19 Fasten the lifting tool 800012 to the piston crown by us-ing hexagon socket head screws M12×40 (6), see Fig 11-3.

20 Lift the piston and upper part of connecting rod.

Hydraulic oil

REASSEMBLING 1. Lift the distance sleeve.

2. Lift the hydraulic cylinder and screws in a one package in pos.

3. Connect hoses, open valve.

4. Tighten the tool assembly, until the piston and cylinder is on the same level.

5. Close the valve, pump to required pressure.

Tighten the nuts. Release the pressure slowly.

6. Repeat steps 4, and 5.

7. Open the valve slowly and remove the tool.

21 Mount the piston rings by using the pliers 800001. If rings are reused, take care not to turn them upside down. The rings should be placed with gaps located 120° in relation to each other. The marking “TOP” to be upwards.

Piston ring locations shown in the table below.

Groove # Marking near the ring gap

I “TOP GROOVE I”

II “TOP C99 GROOVE II”

III (oil scraper ring)

22 Lubricate the piston and place the clamp device for pis-ton rings, 800013, around the pispis-ton, checking that the pispis-ton rings slide into their grooves.

23 Mount the guiding plug 800017 in the screw hole on the upper part of the connecting rod, see Fig 11-5.

24 Mount the limiter 800018 for piston inside the cylinder liner.

25 Rotate the crank pin of the cylinder concerned in the BDC by using turning device.

Note! Observe extremely cautiousness always when upper part of the connecting rod and big end are dismantled, when crank-ing the engine.

26 Place the mounting tool 800103 into the cylinder liner.

27 Lower the piston/connecting rod upper part carefully into the cylinder liner.

28 Turn the lower part (5) of the connecting rod straight up-wards. Mount the shim (2).

29 Rotate the crank pin of the cylinder concerned in the TDC.

Check that guiding pins are in right position.

30 Place the upper part of the connecting rod and the big end, take care not to damage the studs and threads. Remove the limiter.

31 Turn the crankshaft counter-clockwise until the nuts can be mounted. Remove the mounting tools.

32 Assemble the hydraulic tools, hoses and proceed with tightening of the nuts in two steps as described in adjacent figure. Tightening torques see section 07.3.

Hydraulic oil

REASSEMBLING 1. Lift the distance sleeve.

2. Lift the hydraulic cylinder and screws in a one package in pos.

3. Connect hoses, open valve.

4. Tighten the tool assembly, until the piston and cylinder is

7. Open the valve slowly and remove the tool.

33 Mount the anti-polishing ring.

Note! Check that the connecting rod is movable axially after tight-ening.