{"id":2834,"date":"2023-11-17T22:50:20","date_gmt":"2023-11-17T21:50:20","guid":{"rendered":"https:\/\/mbci.mackuz.ovh\/?p=2834"},"modified":"2023-11-17T22:50:20","modified_gmt":"2023-11-17T21:50:20","slug":"removal-and-installation-of-pistons","status":"publish","type":"post","link":"https:\/\/mbci.mackuz.ovh\/index.php\/2023\/11\/17\/removal-and-installation-of-pistons\/","title":{"rendered":"Removal and installation of pistons"},"content":{"rendered":"

 <\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
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03\u2014316 Removal and installation of pistons<\/strong><\/div>\n<\/div>\n<\/td>\n
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Coordination piston-cylinder<\/strong><\/div>\n<\/div>\n<\/td>\n
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Engine<\/div>\n<\/div>\n<\/td>\n
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Piston code number<\/div>\n<\/div>\n<\/td>\n
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Group no.<\/div>\n<\/div>\n<\/td>\n
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Standard dimension Std<\/div>\n
Cylinder dia.<\/div>\n<\/div>\n<\/td>\n
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Piston dia.<\/div>\n<\/div>\n<\/td>\n
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All<\/div>\n<\/div>\n<\/td>\n
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10.18<\/div>\n<\/div>\n<\/td>\n
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0 1 2<\/div>\n<\/div>\n<\/td>\n
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90.845 – 90.855 above 90.855 – 90.865 above 90.865-90.875<\/div>\n<\/div>\n<\/td>\n
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90.898 – 90.908 above 90.908-90.918 above 90.918-90.928<\/div>\n<\/div>\n<\/td>\n
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Piston standout<\/strong><\/div>\n<\/div>\n<\/td>\n
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\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n
<\/td>\n\n
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Distance between piston crown and cylinder crankcase parting surface<\/div>\n<\/div>\n<\/td>\n
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standout max. 0.9 standout min. 0.5<\/div>\n<\/div>\n<\/td>\n
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Test values<\/strong><\/div>\n<\/div>\n<\/td>\n
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When new<\/div>\n<\/div>\n<\/td>\n
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Wear limit<\/div>\n<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
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Piston clearance<\/div>\n<\/div>\n<\/td>\n
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0.043-0.063<\/div>\n<\/div>\n<\/td>\n
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0.12<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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Difference in weight of pistons in one engine<\/div>\n<\/div>\n<\/td>\n
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5g<\/div>\n<\/div>\n<\/td>\n
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10 g<\/strong><\/div>\n<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
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Piston pin dia.<\/div>\n<\/div>\n<\/td>\n
\n
\n
27.995-28.000<\/div>\n<\/div>\n<\/td>\n
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<\/div>\n

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<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/td>\n<\/td>\n<\/tr>\n
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\n
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in bushing<\/div>\n<\/div>\n<\/td>\n
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0.018-0.029<\/div>\n<\/div>\n<\/td>\n
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<\/div>\n<\/div>\n

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<\/td>\n\n
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Piston pin clearance<\/div>\n<\/div>\n<\/td>\n
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in piston<\/div>\n<\/div>\n<\/td>\n
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0.00-0.01<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Gap clearance of piston rings<\/div>\n<\/div>\n<\/td>\n
\n
\n
groove 1 groove 2 groove 3<\/div>\n<\/div>\n<\/td>\n
\n
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0.20-0.40 0.15-0.35 0.20-0.45<\/div>\n<\/div>\n<\/td>\n
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1.5 1.0 1.0<\/div>\n<\/div>\n<\/td>\n
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Side clearance of piston rings<\/div>\n<\/div>\n<\/td>\n
\n
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groove 1 groove 2 groove 3<\/div>\n<\/div>\n<\/td>\n
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0.110-0.142 0.070-0.112 0.030-0.062<\/div>\n<\/div>\n<\/td>\n
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0.20 0.15 0.1<\/div>\n<\/div>\n<\/td>\n
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<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Tightening torque<\/strong><\/div>\n<\/div>\n<\/td>\n
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initial torque<\/div>\n<\/div>\n<\/td>\n
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40-50 Nm<\/div>\n<\/div>\n<\/td>\n
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Connecting rod nuts<\/div>\n<\/div>\n<\/td>\n
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angle of rotation torque 90-100\u00b0<\/div>\n<\/div>\n<\/td>\n
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<\/div>\n<\/div>\n

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<\/td>\n\n
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03.8-316\/1 F2<\/div>\n<\/div>\n<\/td>\n
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Special tools<\/strong><\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Expanding pliers for piston rings<\/div>\n<\/div>\n<\/td>\n
\n
\"om617<\/div>\n<\/td>\n
\n
\n
000 589 51 37 00<\/div>\n<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Clamping strap for piston rings<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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000 589 04 14 00<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Angle of rotation tool<\/div>\n<\/div>\n<\/td>\n
\n
\"om617<\/div>\n<\/td>\n
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116 589 01 13 00<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Note<\/strong><\/div>\n<\/div>\n<\/td>\n
\n
\"om617<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
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The group number 0, 1 or 2, the piston code number, e.g. 10 and the driving direction arrow are punched into piston crown.<\/div>\n
The group number is also punched into cylinder crank-case parting surface.<\/div>\n
Both group numbers (cylinder bore and piston) must be in agreement.<\/div>\n<\/div>\n<\/td>\n
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1034-8235<\/strong><\/div>\n<\/div>\n<\/td>\n
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The specified piston clearance will then be maintained.<\/div>\n
In the event of repairs, hone cylinder bores to dimen\u00adsions of available piston plus piston clearance.<\/div>\n
The piston shank is graphite-treated.<\/div>\n
Due to the higher thermic load, the pistons are cooled by means of an annular duct located in piston crowns (functional description refer to 18\u2014040).<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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1034-8120<\/strong><\/div>\n<\/div>\n<\/td>\n
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03.8-316\/2<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

 <\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
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<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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<\/td>\n\n
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Removal<\/strong><\/div>\n<\/div>\n<\/td>\n
\n
\"om617<\/div>\n<\/td>\n
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<\/td>\n\n
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Attention!<\/strong><\/div>\n
To avoid damage to oil spray nozzles caused by con\u00adtact with connecting rod during removal of piston, remove oil spray nozzles (arrow) first (18\u2014040).<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
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<\/div>\n<\/div>\n

 <\/td>\n

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Removal<\/strong><\/div>\n<\/div>\n<\/td>\n
\n
\"om617<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
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1 Remove connecting rod with piston in upward direction.<\/div>\n<\/div>\n<\/td>\n
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2 <\/em>Remove piston pin lock and force out piston pin.<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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03.8-316\/3<\/div>\n<\/div>\n<\/td>\n
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3 Recondition and square connecting rod (03\u2014313).<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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<\/td>\n\n
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Installation<\/strong><\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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4 Place piston on connecting rod in such a manner that the arrow (1) is pointing in driving direction and the lock nuts (2) in connecting rod are pointing to lefthand engine side.<\/div>\n
Attention!<\/strong><\/div>\n
Do not heat piston.<\/div>\n<\/div>\n<\/td>\n
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5 Push-in piston pin coated with engine oil manually.<\/strong><\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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103-155?1<\/div>\n<\/div>\n<\/td>\n
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6\u00a0 \u00a0Place piston pin lock into groove. Check piston rings for easy operation.<\/div>\n
When installing used pistons, check piston rings for gap and side clearance.<\/div>\n
7\u00a0 \u00a0 Lubricate clean cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons.<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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03.8-316\/4<\/div>\n<\/div>\n<\/td>\n
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 <\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
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8\u00a0 \u00a0Distribute gaps of piston rings uniformly along circumference of piston.<\/div>\n
9\u00a0 \u00a0Position piston ring clamping strap and insert piston.<\/div>\n
The arrow in piston crown should point in driving direction.<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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10\u00a0 \u00a0Place connecting rod bearing cap with code numbers facing each other on connecting rod, lubri\u00adcate connecting rod nuts, tighten to 40\u201450 Nm preload and 90\u2014100\u00b0angle of rotation torque.<\/div>\n
11\u00a0 \u00a0 Rotate crankshaft and check clearance between piston pin eye and connecting rod.<\/div>\n
12\u00a0 \u00a0 In TDC position of pistons, measure distance between piston crown and cylinder crankcase parting surface (refer to table).<\/div>\n<\/div>\n<\/td>\n
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\"om617<\/div>\n<\/td>\n
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<\/div>\n<\/div>\n

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13 Install oil spray nozzles (18-040).<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

<\/td>\n<\/tr>\n
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Piston and connecting rod<\/div>\n<\/div>\n<\/td>\n
<\/td>\n<\/tr>\n
<\/td>\n\n
\n
<\/div>\n<\/div>\n

 <\/td>\n

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1\u00a0 \u00a0 \u00a0Piston<\/div>\n
2\u00a0 \u00a0 \u00a02 piston pin locks<\/div>\n
3a\u00a0 \u00a0Rectangular ring 3 mm<\/div>\n
3b\u00a0 \u00a0Rectangular ring 2 mm<\/div>\n
3c\u00a0 \u00a0Chamfered oil ring with expanding spring<\/div>\n
4\u00a0 \u00a0 \u00a0Piston pin<\/div>\n
5\u00a0 \u00a0 \u00a0Connecting rod<\/div>\n
6\u00a0 \u00a0 \u00a0Connecting rod bushing<\/div>\n
7\u00a0 \u00a0 \u00a02 connecting rod bolts<\/div>\n
8\u00a0 \u00a0 \u00a0Connecting rod bearing upper and lower half<\/div>\n
10\u00a0 \u00a0 \u00a0Connecting rod bearing cap<\/div>\n
11\u00a0 \u00a0 \u00a02 connecting rod nuts<\/div>\n<\/div>\n<\/td>\n
\n
\n
<\/div>\n
<\/div>\n
1033 7786\/1<\/strong><\/div>\n
\"om617<\/div>\n<\/div>\n<\/td>\n
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<\/td>\n\n
\n
<\/div>\n<\/div>\n

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03.8-316\/5 F2<\/div>\n<\/div>\n<\/td>\n
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 <\/p>\n","protected":false},"excerpt":{"rendered":"

    03\u2014316 Removal and installation of pistons   Coordination piston-cylinder   Engine Piston code number Group no. Standard dimension Std Cylinder dia. Piston dia.   All 10.18 0 1 2 90.845 – 90.855 above 90.855 – 90.865 above 90.865-90.875 90.898 – 90.908 above 90.908-90.918 above 90.918-90.928   Piston standout   Distance between piston crown and cylinder crankcase parting surface standout max. 0.9 standout min. 0.5   Test values When new Wear limit Piston clearance 0.043-0.063 0.12 Difference in weight of pistons in one engine 5g 10 g Piston pin dia. 27.995-28.000     in bushing 0.018-0.029   Piston pin clearance   in piston 0.00-0.01   Gap clearance of piston rings groove 1 groove 2 groove 3 0.20-0.40 0.15-0.35 0.20-0.45 1.5 1.0 1.0   Side clearance of piston rings groove 1 groove 2 groove 3 0.110-0.142 0.070-0.112 0.030-0.062 0.20 0.15 0.1   Tightening torque   initial torque 40-50 Nm   Connecting rod nuts   angle of rotation torque 90-100\u00b0   03.8-316\/1 F2       Special tools   Expanding pliers for piston rings 000 589 51 37 00   Clamping strap for piston rings 000 589 04 14 00   Angle of rotation tool 116 589 01 13 00   Note The group number 0, 1 or 2, the piston code number, e.g. 10 and the driving direction arrow are punched into piston crown. The group number is also punched into cylinder crank-case parting surface. Both group numbers (cylinder bore and piston) must be in agreement. 1034-8235   The specified piston clearance will then be maintained. In the event of repairs, hone cylinder bores to dimen\u00adsions of available piston plus piston clearance. The piston shank is graphite-treated. Due to the higher thermic load, the pistons are cooled by means of an annular duct located in piston crowns (functional description refer to 18\u2014040).   1034-8120   03.8-316\/2       Removal Attention! To avoid damage to oil spray nozzles caused by con\u00adtact with connecting rod during removal of piston, remove oil spray nozzles (arrow) first (18\u2014040).   Removal 1 Remove connecting rod with piston in upward direction.   2 Remove piston pin lock and force out piston pin.   03.8-316\/3       3 Recondition and square connecting rod (03\u2014313).   Installation 4 Place piston on connecting rod in such a manner that the arrow (1) is pointing in driving direction and the lock nuts (2) in connecting rod are pointing to lefthand engine side. Attention! Do not heat piston.   5 Push-in piston pin coated with engine oil manually. 103-155?1   6\u00a0 \u00a0Place piston pin lock into groove. Check piston rings for easy operation. When installing used pistons, check piston rings for gap and side clearance. 7\u00a0 \u00a0 Lubricate clean cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons.   03.8-316\/4       8\u00a0 \u00a0Distribute gaps of piston rings uniformly along circumference of piston. 9\u00a0 \u00a0Position piston ring clamping strap and insert piston. The arrow in piston crown should point in driving direction.   10\u00a0 \u00a0Place connecting rod bearing cap with code numbers facing each other on connecting rod, lubri\u00adcate connecting rod nuts, tighten to 40\u201450 Nm preload and 90\u2014100\u00b0angle of rotation torque. 11\u00a0 \u00a0 Rotate crankshaft and check clearance between piston pin eye and connecting rod. 12\u00a0 \u00a0 In TDC position of pistons, measure distance between piston crown and cylinder crankcase parting surface (refer to table).   13 Install oil spray nozzles (18-040).   Piston and connecting rod   1\u00a0 \u00a0 \u00a0Piston 2\u00a0 \u00a0 \u00a02 piston pin locks 3a\u00a0 \u00a0Rectangular ring 3 mm 3b\u00a0 \u00a0Rectangular ring 2 mm 3c\u00a0 \u00a0Chamfered oil ring with expanding spring 4\u00a0 \u00a0 \u00a0Piston pin 5\u00a0 \u00a0 \u00a0Connecting rod 6\u00a0 \u00a0 \u00a0Connecting rod bushing 7\u00a0 \u00a0 \u00a02 connecting rod bolts 8\u00a0 \u00a0 \u00a0Connecting rod bearing upper and lower half 10\u00a0 \u00a0 \u00a0Connecting rod bearing cap 11\u00a0 \u00a0 \u00a02 connecting rod nuts 1033 7786\/1   03.8-316\/5 F2        <\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_crdt_document":"","footnotes":""},"categories":[47,44],"tags":[],"class_list":["post-2834","post","type-post","status-publish","format-standard","hentry","category-crankshaft-assembly-om617","category-om617"],"aioseo_notices":[],"featured_image_src":null,"author_info":{"display_name":"mackuz","author_link":"https:\/\/mbci.mackuz.ovh\/index.php\/author\/mackuz\/"},"_links":{"self":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2834","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/comments?post=2834"}],"version-history":[{"count":1,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2834\/revisions"}],"predecessor-version":[{"id":2835,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/posts\/2834\/revisions\/2835"}],"wp:attachment":[{"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/media?parent=2834"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/categories?post=2834"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/mbci.mackuz.ovh\/index.php\/wp-json\/wp\/v2\/tags?post=2834"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}