Removal
1. Remove the cylinder head (see the relevant chapter).
2. Remove the oil pump 2 (see the relevant chapter) and strengthening of 1 cylinder block (see illustration).
3. Mark the mounting position of the pistons, caps and connecting rod bearing shells 3. Connecting rods 4 and their caps have the same markings (see illustration 8.2).
4. Remove carbon deposits from the top of the cylinders and remove the corresponding piston together with the connecting rod.
5. Unscrew the mounting bolts and remove the 2 connecting rod caps 3 (see illustration).
6. Place the removed connecting rod caps together with the liners so that you can later install them in their original places.
Attention! According to the color marking 1, one bearing shell with red marking and one shell with blue marking must be installed in each bearing. The shell with the marking "S" is the upper shell.
7. Install tool 4 KM-J-41742 into the connecting rod (see illustration).
8. Lubricate the pistons and their rings with a thin layer of motor oil.
9. Install the rings on the pistons, positioning their locks at 120° relative to each other.
10. Compress the rings with a special device 1 and insert the piston with the connecting rod into the cylinder bore. The arrow on the piston bottom should be facing the valve timing drive (see illustration).
Attention! When installing the piston with the connecting rod, the corresponding connecting rod journal must be in a position in which the installed piston is located at TDC or before TDC.
11. Tap the piston with the handle of a hammer until it is completely seated in the cylinder bore.
12. Place the connecting rod with the piston secured to it using the tool 2 KM-J-41742 on the corresponding journal and remove the tool (see illustration).
13. Place the connecting rod bearing shells, following the color markings on them, install the connecting rod caps, screw in the new bolts for fastening them and tighten them with a force of 20 Nm, followed by an additional turn of 60°.
14. Place the reinforcing frame on the cylinder block so that arrow 1 on it faces the timing drive, and secure it with a force of 22 Nm (see illustration).
15. Install the oil pump and cylinder head.
Piston rings - removal and installation
16. Remove the piston from the cylinder bore together with the connecting rod.
17. Remove the piston rings using pliers (see illustration).
18. Clean the rings and their grooves on the piston. You can use the old ring to clean the grooves.
19. Check the clearance between the piston rings and their grooves using feeler gauges (see illustration).
20. Check the gap in the piston ring lock using feeler gauges by inserting the rings into the gauge (see illustration).
Permissible clearance in the piston ring lock:
- upper compression ring - 0.20-0.40 mm,
- lower compression ring - 0.40-0.65 mm,
- oil scraper ring - 0.25-0.45 mm.
21. Install the piston rings into the grooves using pliers so that the "TOP" inscription on them faces up (see illustration), and their locks were located at 120° relative to each other.
Piston - replacement
22. Remove the piston from the cylinder bore together with the connecting rod.
23. Remove thrust ring 1 from the piston pin using pointed pliers or another suitable tool and press out the pin (see illustration). Attention! The piston and piston pin are matched to each other and their rearrangement is not allowed.
24. Before installing the piston, measure the calculated clearance between the piston and the cylinder by measuring the piston diameter with a micrometer at several points at a distance of 90° from each other, stepping back from its skirt by 7 mm (see illustration).
25. Measure the cylinder bore diameter using a bore gauge in three zones (see illustration).
The gap between the piston and the cylinder in new engines is 0.031-0.063 mm, while in used engines it can reach 0.15 mm.
Example of measurements:
- cylinder bore diameter - 80,000mm
- piston outer diameter - 79.955mm
- gap 0.045 mm
26. Install the connecting rod head into the piston, following mark 1 on the connecting rod and the arrow on the piston bottom, which should face the timing drive after installing the connecting rod and piston group into the cylinder block (see illustration).
27. Lubricate the piston pin with engine oil and press it in by hand up to the thrust ring seat groove.
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28. Lock the piston pin with thrust ring 2. The ends of the ring should rest against the corresponding protrusion (see arrow in illustration).
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