Removal and installation of the piston group (Freelander 1)

Dismantling

1. Remove the connecting rod bearings.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Replacement of connecting rod bearings.

2. Remove carbon deposits from the top of the cylinders.

3. Do not allow the LRT-12-144 cylinder liner fasteners to protrude above the cylinder bore.

4. Mark the pistons with connecting rods so that you can later install them in their original places.

5. Carefully push the pistons toward the top of the cylinders.

6. Carefully push the pistons out, making sure that the lower connecting rod heads do not touch the cylinder bore. CAUTION: Removing the pistons entails replacing the cylinder liner seals.

7. Using special pliers, remove the rings from the pistons and dispose of the rings.

Installation

1. Clean the piston ring grooves and blow out the oil holes in the ring grooves.



2. Having installed the rings at a distance of 20 mm from the upper edge of the cylinder liner, as shown in the figure, check the size of the gap in the ring lock.

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

ATTENTION: The gap in the ring lock must be checked strictly in the cylinder for which these rings are intended.

3. Check the pistons for damage and cracks.

4. Measure the diameter of the piston skirt at a right angle to the axis of the piston pin, at a distance of 8 mm from the lower edge of the skirt.

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

NOTE: The designation of size groups A or B is stamped on the upper surface of the piston bottom.

5. Starting with the piston of the first cylinder, check the clearance between the skirt and the cylinder bore. With the piston upside down, insert it into the cylinder with the 'FRONT' mark or arrow on the bottom facing the REAR of the engine.

[The original text can be found at: LRMAN.ru]

CAUTION: Each piston must be checked in its own cylinder.

6. The lower edge of the piston skirt should be located at a distance of 30 mm from the upper part of the cylinder liner.

7. Using a feeler gauge, measure and record the clearance between the piston and the left side of the cylinder liner (as viewed from the front of the engine).

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

8. Repeat this procedure with the remaining pistons.

NOTE: Piston is supplied complete with connecting rod only.

9. Install the expander on the oil scraper ring.

10. Turning the rings with the 'TOP' mark, or another mark, upwards, using pliers to spread the rings, put on the piston: oil scraper ring, 2nd compression ring and upper compression ring.



11. Check the freedom of movement of the rings in the grooves and move the locks A and B of the compression rings at an angle of 120° to each other and away from the loaded part of the piston. The gap C of the oil scraper ring and the lock D of the ring expander are moved opposite each other, in a plane located at an angle of 30° to the axis of the piston pin.



12. Check the clearance between the new ring and the piston groove.

TECHNICAL SPECIFICATIONS, Engine - petrol K1.8.

13. Remove the bolts from the LRT-12-144 cylinder liner fasteners and remove the fasteners. If you intend to use the old cylinder liners, mark the position of each liner relative to the cylinder block with a felt-tip pen. DO NOT scratch or punch the cylinder liners.

CAUTION: Store the cylinder head bolts in the order they were on the assembled engine.

14. Using your hand, push the sleeve outward towards the cylinder head.



15. Measure the wear and taper of the liners in two directions, at a distance of 65 mm from the top edge of the liner. RED group = 80.000-80.015 mm. BLUE group = 80.016-80.030 mm. Dimension groups A and B are marked on the outside of the cylinder liners.

CAUTION: Cylinder liners with excessively rubbed, worn, scratched or scored cylinder bore surfaces must be replaced. DO NOT ATTEMPT to hone or remove rubbing from the cylinder bore surface. If old liners are to be reused, retain the position marks when removing the liners.

16. The cylinder diameter and landing height size group are determined by the manufacturer. The diameter size group (red, A or B, blue) and landing height group (V or Z) are applied to the outer surface of the liners together with the part number. If the cylinder liner (liners) is to be replaced, the new liner (liners) must have the same landing height group as the one being replaced. Any cylinder diameter size group is supplied in two landing height size groups.



17. Remove any remaining sealant from the cylinder block and from the cylinder liner flange (if further use is intended).

18. Wash the cylinder liners and wipe them dry.



19. Apply a continuous bead of RTC 3347 sealant 2mm thick along the flange of each liner as shown.

20. Holding the sleeve at a right angle to the top surface of the block, push the sleeve into the block until the shoulder stops against the seating belt. DO NOT ALLOW the sleeve to FALL into the cylinder block.



21. Install the cylinder liner fasteners with the nylon nuts included in the kit, LRT-12-144, on the cylinder block and secure them with the cylinder head fastening bolts. The base of the cylinder liner fasteners should not protrude above the cylinder bore.

CAUTION: The bolts used must be screwed into the same sockets in which they were located on the assembled engine.

22. Lubricate the cylinder bore, pistons and rings with engine oil, check that the ring locks are spaced apart from each other at the required angle.



23. One at a time, crimp the rings on each piston with the mandrel, LRT-12-204, and with the piston facing forward with the 'FRONT' mark stamped on the bottom, insert the pistons into their cylinders so that the bottom is flush with the top edge of the liner. Remove the ring crimping tool.

24. Install the connecting rod bearings.

ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Replacement of connecting rod bearings.