Perkins New 1000 Series, Workshop Manual, Page: 72 / 290

13
72 Workshop Manual, TPD 1350, issue 3
New 1000 Series
Piston and connecting rod assembly
To dismantle and to assemble 13-6
Caution: The pistons and connecting rods are
matched to the relevant cylinder. Note the position of
each connecting rod and piston for correct assembly.
To dismantle
1 Remove the piston rings , see operation 13-5 .
2 Remove the circlips which retain the gudgeon pin.
Caution: Make a temporary mark on the piston. Do
not scratch, etch or stamp the piston surface.
3 Put a temporary mark on the piston to indicate the
cylinder number as shown on the connecting rod. Put
the temporary mark on the piston on the same side as
the mark on the big end to ensure that they are
assembled correctly (A).
4 Push the gudgeon pin out by hand. If the gudgeon
pin is tight, heat the piston to 40/50°C (100/120°F) for
easy removal of the gudgeon pin.
5 Inspect the piston and connecting rod assembly ,
see operation 13-8 and operation 13-9 .
To assemble
1 Clean the bore of the small end bush and lubricate
it with clean engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of the
gudgeon pin bosses. Ensure that it fits correctly in the
groove.
3 With the piston upside down, put the connecting rod
in position with the recess for the location of the big
end bearing (B1) on the same side as the recess in
the gudgeon pin boss (B2). If the original piston is
used, ensure that it is assembled to the correct
connecting rod and is used in the original cylinder.
New 1000 Series engines have six connecting rod
length grades, if a new connecting rod is fitted, ensure
that it is of the correct length grade
, see operation 13-
7 .
4 Lubricate the gudgeon pin bosses with clean
engine lubricating oil and push in the gudgeon pin
towards the circlip. If the gudgeon pin is a tight fit in
the piston, heat the piston to 40/50 °C (100/120 °F)
before the gudgeon pin is fitted.
5 Fit a new circlip in the groove in the other gudgeon
pin boss. Ensure that it fits correctly in the groove.
6 Fit the piston rings , see operation 13-5 .
4
4
A
A0354
1
2
B
A0086A
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