ar0310b7021b

Remove/install piston

Tipo ar · tema 03.10 · versione 0204 · 2020-06-05

Valido per: Engine 904.9, 906.9 (except 906.999), 924.9 (except 924.92), 926.9 (except 926.942) in model 368.0/1, 382.1 (except 382.171/176), 384.06/07, 634.0, 685.282/284/289/290, 979.2

Non disponibile in “it”; mostrato in Inglese.

Collocazione

Gruppo funzionale 1 Motore › 03 Manovellismo › 03.10 Bielle e pistoni — Serie 368 (modelli 0**, 1**) · Serie 382 (modelli 111, 123, 134, 135, 143, 153, 154, 155, 156, 157, 158, 175, 177, 178, 180, 181, 182, 184, 185, 186, 187, 188, 189, 190) · Serie 384 (modelli 06*, 07*) · Serie 634 (modelli 0**) · Serie 685 (modelli 282, 284, 289, 290) · Serie 904 (modelli 9**) · Serie 906 (modelli 900, 901, 902, 903, 910, 911, 912, 913, 915, 916, 917, 918, 919, 920, 921, 922, 923, 924, 925, 926, 927, 928, 929, 930, 931, 932, 933, 934, 935, 936, 937, 938, 939, 940, 941, 944, 945, 946, 947, 948, 949, 950, 951, 952, 953, 954, 955, 956, 960, 961, 963, 964, 965, 966, 967, 970, 972, 973, 974, 975, 977, 982, 983, 984, 985, 987, 988, 989, 990, 991, 992, 993, 994, 995, 998) · Serie 979 (modelli 2**)

EinPAS 15 Motore › 15.15 Motore a combustione interna completo/basamento motore/manovellismo › 15.15.40 Biella/pistone — Serie 368 (modelli 0**, 1**) · Serie 382 (modelli 111, 123, 134, 135, 143, 153, 154, 155, 156, 157, 158, 175, 177, 178, 180, 181, 182, 184, 185, 186, 187, 188, 189, 190) · Serie 384 (modelli 06*, 07*) · Serie 634 (modelli 0**) · Serie 685 (modelli 282, 284, 289, 290) · Serie 904 (modelli 9**) · Serie 906 (modelli 900, 901, 902, 903, 910, 911, 912, 913, 915, 916, 917, 918, 919, 920, 921, 922, 923, 924, 925, 926, 927, 928, 929, 930, 931, 932, 933, 934, 935, 936, 937, 938, 939, 940, 941, 944, 945, 946, 947, 948, 949, 950, 951, 952, 953, 954, 955, 956, 960, 961, 963, 964, 965, 966, 967, 970, 972, 973, 974, 975, 977, 982, 983, 984, 985, 987, 988, 989, 990, 991, 992, 993, 994, 995, 998) · Serie 979 (modelli 2**)

Valido anche per motori/cambi: 924 91*, 924 93*, 924 94*, 924 97*, 924 98*, 924 99*, 926 900, 926 910, 926 911, 926 912, 926 913, 926 914, 926 915, 926 916, 926 917, 926 918, 926 919, 926 920, 926 921, 926 924, 926 925, 926 926, 926 927, 926 928, 926 929, 926 930, 926 932, 926 933, 926 934, 926 935, 926 937, 926 938, 926 941, 926 945, 926 946, 926 947, 926 948, 926 949, 926 950, 926 956, 926 959, 926 960, 926 961, 926 969, 926 970, 926 971, 926 972, 926 973, 926 974, 926 975, 926 976, 926 985, 926 986, 926 987, 926 988, 926 989, 926 990, 926 991, 926 992, 926 993, 926 994, 926 995, 926 996, 926 997, 926 998, 926 999

AR03.10-B-7021B

Remove/install piston

18.05.2020

Engine

904.9, 906.9 (except 906.999), 924.9 (except 924.92), 926.9 (except 926.942) in model 368.0/1, 382.1 (except 382.171/176), 384.06/07, 634.0, 685.282/284/289/290, 979.2

Remove/install piston

1

Piston

2

Piston pin

3

Lock-ring

4

Connecting rod

5

Connecting rod cap

6

Bolt

7

Connecting rod shells

W03.10-0005-06

Remove/install piston

1

Piston

2

Piston pin

4

Connecting rod

5

Connecting rod cap

7

Connecting rod shells

8

Oil injector

W03.10-0006-06

Remove/install piston

1

Piston

4

Connecting rod

6

Bolt

9

Compression belt

A

Distance between the piston lower face and the crankcase face

L

Connecting rod cap bolts length

W03.10-0007-06

Remove

1

Remove the cylinder head


Engine 904.9, 924.9

AR01.30-B-5800B

Engine 906.9, 926.9

AR01.30-B-5800J

2

Remove oil sump


.

AR01.45-B-7500B

3

Remove the residues of combustion from the cylinder internal upper part

Take care in order to not damage the cylinder internal surface.

Procedure to prevent damages to the piston rings, when removing the piston.

4

Remove the connecting rod cap (5)


.

AR03.10-B-6111B

Turn the crankshaft until obtaining a favorable position to release and remove the bolts (6) and the connecting rod cap (5).

Be careful not to damage the connecting rod (4).

In the case of damages to the coupling faces of the connecting rod cap (5) and the connecting rod (4), replace the complete connecting rod.

5

Remove the piston (1) with the connecting rod (4) from the crankcase


Injector stuck due to interference.

AR18.00-B-4000E

Injector stuck due to bolt.

AR18.00-B-4000C

If necessary, correct or replace the oil spray injector (8)

Be careful not to damage the connecting rod (4), the crankshaft journal, the cylinder surface and the piston oil injector (8).

Turn the crankshaft until the piston (1) to be removed is in the TDC (top dead center) . Push the connecting rod (4) with the piston (1) out of the cylinder, with the aid of a wooden or plastic handle.

6

Remove the connecting rod shells (7) from the connecting rod (4) and from the connecting rod cap (5)

Mark the connecting rod shells (7), those of the connecting rod (4) and those of the cap (5).
This procedure will allow, in the case of reuse, that the shells (7) are installed in their original positions. For engines 904 above 100kW, engines 906 above 170 kW and all the 924 and 926 engines, the shell (7) assembled in the connecting rod (4) receives a special treatment (in order to resist to higher loads), differently from the shell (7) assembled in the cap (5).

7

Remove the locking rings (3)

Secure the connecting rod (4) on a vise with its jaws protected with a soft material.

8

Remove the piston pin (2) and remove the piston (1) from the connecting rod (4)

Should the piston (1) be reused, keep it with its respective pin.

.Piston pin diameter

*BE03.10-B-1005-02J

.Piston pin hole

*BE03.10-B-1004-02J

Check

9

Check the cylinders and piston (1) for damages and/or wear


Engine 904.9, 906.9, 924.9, 926.9

AR01.00-B-0001A

.

AR01.40-B-9202A

Replace the piston (1) that presents cracks, damages in the lock rings grooves, signs of frictional corrosion and erosion.

10

Check the correspondence between the piston (1) and the cylinder (diameter and height)


.

AR03.10-B-7021-02D

Mandatory procedure when replacing the piston (1) and after reworking the cylinder and/or the crankcase upper face.

11

Check the connecting rod (4) for irregularities


.

AR03.10-B-6111B

12

Check the connecting rod shells (7) and the respective crankshaft journal


.

AR03.10-B-6111-06B

13

Check the rings state for wearing and/or cracks in the external layer


.

AR03.10-B-7311B

Replace the damaged rings.

14

Check the length (L) of the connecting rod cap screws

Replace the bolt (6) in case the connecting rod screw max. length (L) is exceeded.

.Connecting rod bolt

*BE03.10-B-1013-01C

Install

15

Mount the piston (1) to the connecting rod (4), insert the piston pin (2) manually and install the lock rings (3) in the grooves of the piston (1)

Notes on installing pistons and connecting rods

.

AH03.10-N-2200-02C


Care must be taken when assembling the piston (1)
Otherwise, it may collide with the piston cooling nozzle

Note that, when assembling the engine, the arrow at the piston bottom (1) is oriented towards the front of the engine and the connecting rod (4), with the shorter side (mating face with the cap) facing the injection units.

Lubricate the piston pin (2) with engine oil.

16

Place the rings on the piston (1) so that their openings are lagged from each other by approximately 120o

Lubricate the piston (1) and the rings with engine oil.

17

Mount the ring compression belt (9) onto the piston (1) and compress the rings to the outer diameter of the piston

Tensioning strap

*000589383100

18

Install the connecting rod shell (7) on the connecting rod (4)

Pay attention to the marks made during the removal. Fit the shell tab in the connecting rod slot.

Lubricate the friction surface of the shell.

19

Insert into the crankcase, the connecting rod (4) with the piston (1), until the compression belt (9) touches the crankcase


Injector fixed by bolt.

AR18.00-B-4000C

Injector fixed by interference.

AR18.00-B-4000E

If necessary, correct or replace the injector nozzle (8) following the steps described above.

Take care to not damage the oil injector (8).

The arrow on the piston bottom (1) must face the engine front side and the connecting rod, with the shorter side (face of junction to the cover) turned to the injector units.

20

Carefully push the piston (1) until the connecting rod shell (7) is seated on the crankshaft journal

Be careful not to damage the connecting rod (4), the crankshaft journal and the cylinder surface.

21

Install the connecting rod shell (7) in the connecting rod cap (5)

Pay attention to the marks made during the removal. Fit the connecting rod shell (7) tab to the connecting rod cap groove (5).
Lubricate the friction surface of the connecting rod shell (7)..

22

Install the connecting rod cap (5) with the connecting rod shell (7)

Pay attention to ensure that the connecting rod (4) identification numbers match the numbers on the corresponding cap (5), and that they are facing the same side. Manually press the cap (5) on the crankshaft journal, fitting it into the connecting rod (4).

23

Install the bolts (6)

Slightly lubricate the thread and the seating face of the screw head (6).

Do not reuse the bolts that have their length (L) above the maximum admissible value.

.Connecting rod bolt

*BE03.10-B-1013-01C

.Attachment bolt for the connecting rod cover

*BA03.10-B-1001-01B

24

Check the axial play of the connecting rod (4) and rotate the crankshaft to check the free movement

.Connecting for play (with sleeves) in the crankshaft neck

*BE03.10-B-1003-01C

25

Check the distance between the upper face of the piston (1) at TDC above the crankcase surface


.

AR03.10-B-7041-01D

.Piston oversize at the OT (top dead center) to the upper corner of the engine block

*BE03.10-B-1003-02J

26

Install the oil sump


.

AR01.45-B-7500B

27

Install the cylinder head


Engine 904.9, 924.9

AR01.30-B-5800B

Engine 906.9, 926.9

AR01.30-B-5800J

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1003-01C

Connecting for play (with sleeves) in the crankshaft neck

radial

mm

0,029...0,088

0,029...0,088

axial

mm

0,170...0,470

0,170...0,470

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1003-01C

Connecting for play (with sleeves) in the crankshaft neck

radial

mm

0,029...0,088

0,029...0,088

axial

mm

0,170...0,470

0,170...0,470

Test values for the piston

Number

Designation

Engine 926.950

BE03.10-B-1003-02J

Piston oversize at the OT (top dead center) to the upper corner of the engine block

mm

0,28...0,50

Test values for the piston

Number

Designation

Engine 926.950

BE03.10-B-1004-02J

Piston pin hole

mm

42,003...42,009

Test values for the piston

Number

Designation

Engine 926.950

BE03.10-B-1005-02J

Piston pin diameter

mm

41,995...42,000

Connecting rod test values

Number

Designation

Engine 904.9, 906.9 to 456372

Engine 904.9, 906.9 from 456373

BE03.10-B-1013-01C

Connecting rod bolt

Thread

M

12 x 1,25

12 x 1,25

Length (L) - new bolt

mm

55,5...56,0

55,5...56,0

Length (L) - used bolt

mm

57,0

57,0

Connecting rod test values

Number

Designation

Engine 924.9, 926.9 without Code MS5

Engine 924.9 and 926.9 with Code MS5

BE03.10-B-1013-01C

Connecting rod bolt

Thread

M

12 x 1,25

12x1,25

Length (L) - new bolt

mm

55,5...56,0

56,0

Length (L) - used bolt

mm

57,0

57,0

Connecting rod

Number

Designation

Engine 902.9, 904.9, 906.9

Engine 924.9, 926.9

BA03.10-B-1001-01B

Attachment bolt for the connecting rod cover

1st stage

Nm

10

10

2nd stage

Nm

40...50

40...50

3rd stage

Graus

90...100

90...100

Remove/install piston

000 589 38 31 00

Tensioning strap

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