Contents: Removal ↡ Installation ↡
Removal
1. Remove the engine.
2. Remove the cylinder head.
3. Remove the oil pan.
4. Remove the connecting rod caps 5 (see figure 2.51). Mark connecting rod 4 and cover 5 (arrow).
Figure 2.51. Removing and installing pistons:
1. Locking ring,
2. Piston pin,
3. Piston,
4. Connecting rod,
5. Connecting rod cover,
7. Connecting rod cap bolts,
8. Guide tape.
5. Check the condition of the connecting rod cap mounting bolts. Bolt length: 51.7-52.0 mm. Maximum length: 52.9 mm.
6. Remove the piston together with the connecting rod upwards.
7. Remove retaining ring 1. Be careful not to damage the piston.
8. Push piston pin 2 outward and remove the piston from the connecting rod.
Installation
9. Lubricate piston pin 2 and connecting rod guide bushing.
10. Install piston 3 and connecting rod 4.
11. Insert the piston pin 2 by hand.
12. Insert locking ring 1 into the groove (arrow) of the piston.
13. Lubricate the cylinder walls, connecting rod journals, connecting rod caps and pistons 3.
14. Install the guide tape 7.
15. Install piston 3 in the direction of the arrow or in the opposite direction according to the color marking.
16. Install connecting rod cover 5 and tighten its mounting bolts. Install the covers and connecting rod, aligning the previously made marks on them (arrow).
17. Rotate the crankshaft to check its ease of rotation.
18. Measure the piston protrusion. It should be 0.87-1.23 mm.
19. Install the engine oil pan.
20. Install the cylinder head.
21. Install the engine.