- a) On 4-cylinder petrol engines, remove the cylinder head and oil pan as described in part A of this Chapter.
- b) On 6-cylinder petrol engines, remove the cylinder head, sump and oil pump as described in part B of this Chapter.
- c) On diesel engines, remove the cylinder head, sump, oil pump and, where provided, the oil deflector plate as described in parts of this Chapter.
2. If a pronounced protrusion is found on the top of the cylinder surface, it must be removed with a scraper or reamer before installing new pistons. Such a protrusion indicates significant wear of the cylinder surface.
3. Using a hammer and center punch, paint or something else, mark each connecting rod cap and connecting rod on the ground side surface according to the piston number (see Fig. 11.3). If the engine has been disassembled previously, make sure that the marks on the connecting rods correspond to their numbers. Remember that cylinder #1 is located on the camshaft drive chain side.
Fig. 11.3. Marks on the connecting rod and connecting rod cap
4. Similarly, check the piston bottoms for direction indicators. The arrow on each bottom should point in the direction of the camshaft drive target (see fig. 11.4)On some engines this mark may be covered with a layer of carbon deposits and this should be washed off to check for the mark. In some cases the mark may be worn off; in this case, you should do it with a scraper - do not scratch the piston bottom deeply, but make the mark clearly visible.
Fig. 11.4. Direction arrow on the piston bottom
5. Turn the crankshaft so that pistons 1 and 4 (on a 4-cylinder engine), 1 (on a 5-cylinder engine) or 1 and 6 (on a 6-cylinder engine) reached the bottom dead center (BDC) position.
6. Unscrew the bolts of the first connecting rod cap. Remove the cap and take out the connecting rod bearing (see fig. 11.6). If the insert is to be used, secure it to the lid using adhesive tape.
Fig. 11.6. Removing the connecting rod bearing cap
7. Using the hammer handle, push the piston up and out of the cylinder and remove it from the cylinder head, (be careful not to damage the piston oil cooling nozzles on the cylinder head when removing the pistons, if they are installed). Remove the bearing shell from the connecting rod and secure it with tape.
8. Place the cover on the corresponding connecting rod and tighten it with bolts, which will keep the parts in proper order.
9. Remove the 4th piston parts in the same way (on a 4-cylinder engine) or 6th piston (on a 6-cylinder engine).
10. Turn the crankshaft until the remaining pistons are at BDC and remove them.