35
COMPILER TECO/ATI
ENDORSED
DATE
14.07.2003
REG. CODE
1-5302-616
MODEL N°
50898
DATE OF ISSUE
07-03
REVISION
00
XIII
77
78
79
80
0,10 ÷ 0,20 mm
kgm 3,6 ÷ 3,8 (Nm 35,3 ÷ 37,3)
Pistons
Lubricate the following parts with oil before mounting: the
piston pin, the piston, the cylinder and the big-end bearing
Fit the oil rings onto the pistons (fig. 77) in the following order:
1. Chromed compression seal ring
2. Torsional compression seal ring (with internal bevel facing
upward)
3. Expander oil scraper ring (external bevel facing upward).
Couple the piston rods to the connecting rods manually by pressing
the gudgeon pins in without heating the pistons.
This distance is adjusted with special shims that are inserted
between the bottom surface of the cylinder barrel and the
crankcase (0.1 - 0.2 - 0.3 mm)
Now fit the oil pan after first inserting the appropriate gasket
between the facing surfaces.
Cylinder barrels
Before fitting the cylinders turn the piston rings so that the end gaps
are arranged at intervals of 120° with the end gap of the first
compression ring aligned with the axis of the gudgeon pin.
The lower face of the cylinders are chamfered to permit the easy
insertion of the piston rings. The operation can be simplified,
however, using a normal piston collar tool (code 00365R0770) as
shown in figure 79.
Mount the cylinders to the crankcase as shown in figure 80 and then
bring the pistons up to their respective TDC (top dead centre)
positions. The following must now be checked:
1. that the dots punched on the flywheel (TDC) correspond to the
reference mark on the flywheel-housing
2. that the pistons protrude over the top surface of the cylinders
(fig. 80) by a distance of:
Connecting rods
After having fitted the bushes into the big ends mount the
connecting rods to the crankshaft pins; note that the pistons are
marked with an arrow showing the direction of rotation of the
engine. The combustion chamber, which is offset with respect to
the central axis of the piston, must be turned to face the injector
nozzle side. Mount the connecting rod big end cap ensuring that the
reference numbers are aligned with those punched on the
connecting rod itself (fig. 78). Torque the fixing bolts to:
ENGINE ASSEMBLY
