B1CJ0AK1 - 406D9 XU INJECTION

ASSEMBLY CONNECTING RODS - PISTONS

1 - SPECIAL TOOLS

2 - PISTONS/CONNECTING RODS ASSEMBLY

Fit the gudgeon pin (3) of the first piston on the guide end piece .

Screw the handle [4] by hand to its limit without forcing it .

Place on the base [1] the abutment [2] .

Open the clamp (A) .

Fully unscrew the pressure screws (B) .

IMPERATIVE : when positioning the piston on the support [C], position the surface with the boss upwards .

Position the piston on the support [2] and guide it using the assembly of handle, pin, guide end piece .

Insert the pin (D) .

Screw the pressure screws (B) into contact with the piston .

Tighten the nuts (E) .

Place the connecting rod with its cap (without shells) in the piston and centralise it with the handle/gudgeon pin end piece assembly .

Adjust the connecting rod support (F) position and height to obtain :

• the contact of the support (F) under the connecting rod
• play J : 0.1 mm
• tighten the lock nut (G)
• remove the connecting rod

Place the connecting rods on an electric heater .

Place a scrap of tin solder (H) on each little end .

Heat until the solder melts (a temperature of 250 degrees C) .

IMPERATIVE : oil the gudgeon pins .

Clean off the blob of solder .

Position the connecting rod on the assembly .

Rapidly insert the gudgeon pin fully home .

Wait a few seconds before removing the connecting rod/piston assembly .

Proceed in the same way for the other three assemblies .

WARNING : the success of the operations depends on this being done quickly .

2 - 1 - CONNECTING ROD WITH A LUBRICATION HOLE

Position the piston on the abutment [2] with the arrow and the marking DIST (timing gear) to the top .

Fit the big end to the assembly directing the lubrication hole (I) to the left in relation to the gudgeon pin .

In the engine, the lubrication hole is located on the exhaust side .

2 - 2 - 2ND POSSIBILITY

Place the gudgeon pin (3) on the drift .

Screw the sleeve [4] onto the drift without fully tightening .

The pin (1) must rotate freely .

Onto the base [6] place the support [5] .

Fit the piston on the support [5], position the arrow DT upwards .

Align the assembly with the drift [3] and the gudgeon pin .

Retain the piston using clamp (J) on the positioning base clamp [6] .

Place the connecting rod little end on an electric heating plate .

Place a scrap of tin solder (H) on each little end .

Heat until the solder melts (a temperature of 250 degrees C) .

IMPERATIVE : before fitting : lubricate the gudgeon pin (1) .

WARNING : the success of the operations depends on this being done quickly : the pin must be fitted in a single movement .

Clean off the blob of solder .

Place the connecting rod in the piston, the bearing shell stops (I) positioned as shown in the diagram .

Rapidly insert the gudgeon pin (1) fully home .

Wait a few seconds before removing the connecting rod/piston assembly .

Proceed in the same way for the other three assemblies .

2 - 3 - CONNECTING ROD WITH A LUBRICATION HOLE

Fit the big end to the assembly directing the lubrication hole (K) to the left in relation to the gudgeon pin .

In the engine, the lubrication hole is located on the exhaust side .