Piston: Service and Repair

Fig. 4 Rod bolt positioning:

1. Remove circlips and drive out piston pins, using drift tool No. J35336 or equivalent.
2. Replace rod bolts if necessary. Ensure bolt heads are properly positioned, Fig. 4.

Fig. 5 Piston & rod identification marks:

3. Assemble piston and rod maintaining relationship shown, Fig. 5. When properly assembled, numbered surface of rod will be on oil filter side of engine. The arrow located on top of piston will point toward timing chain and/or casting graph, located on piston pin boss, will be on flywheel side.

Fig. 6 Piston ring positioning:

4. Heat pistons in boiling water. Insert lubricated piston pin into hot piston, then install two new circlips.
5. Install piston rings and stagger gaps 120 degrees apart. On ring B, Fig. 6, reference top should face up.