Piston/Cylinder Assemblies

Overview

Part 2 Of 2:

Dismantling And Assembling Pistons And Cylinders






NOTE: During service procedures, refer to the illustrations above and the information below

1. Install snap ring
- Place new snap ring manually into tapered assembly sleeve 9500/2

2. Engage snap ring
- Using assembly tool 9500/3, push snap ring down until the snap ring engages audibly into the groove of the assembly sleeve 9500/2.

CAUTION: Make sure the snap ring is preassembled with the tapered assembly sleeve on a solid support but only immediately before fitting the assembly to the piston pin bore.

3. Visual check
- Remove assembly tool 9500/3 and visually check snap ring for correct seating in the groove of the tapered assembly sleeve 9500/2.

CAUTION:
- The snap ring may pop out of the assembly sleeve
- Be careful to avoid injury!

4. Preassemble pistons to cylinders
- Preassemble pistons and cylinders on a plastic or wooden support (to protect the cylinder) off the engine.

5. Place preassembled cylinder on studs and place assembly sleeve into position.
- Place preassembled cylinder on studs.
- Place tapered assembly sleeve 9500/2 on piston pin bore.

6. Fit snap ring to piston
- Insert plunger into tapered assembly sleeve.
- The smaller diameter of the plunger is used to provide guidance in the piston pin.
- Use plunger to press the snap ring into the piston pin snap ring groove in the piston.
- The snap ring must engage with an audible click.

NOTE: A helper should be available to press the snap ring into the piston.

Visual Check
Visually check snap rings for correct seating after fitting.

Assembly Note





1. Lift off cylinder head gasket only in this reinforced area (arrows) with a suitable tool. If required, soak sealant residues with adhesive remover, e.g. by Loctite, and remove carefully.





2. The piston pins are fitted with circlips with rotation protection. Replace the circlips whenever the pistons have been dismantled.