Figure 3.69. Special tool and devices for assembling the connecting rod and piston group: 1 - sleeve for installing the piston in the correct position; 2 - stop for installing the piston pin; 3 - device for pressing in the piston pin; 4 - piston stop; 5 - handle; 6 - piston pin guide element
To connect the pin to the connecting rod, you will need a special tool and fixtures (figure 3.69).
Part numbers of special tools and devices for engine disassembly according to the spare parts catalog:
- piston pin pressing tool — 0139-AZ;
- piston stop — 0139-Q (for TU9 engines), 0132-D3Y (for engines TU1—TU2—TU3—TU5);
- piston pin guide element — 0139-P;
- handle - 0139-N;
- piston pin installation stop - 0132-D2Z.
Figure 3.70. Device for pressing the piston pin into the piston: 1 - piston pin; 2 - piston pin guide element; 3 - piston stop; 4 - device; 5 - handle; A - clamp; B - screws
Install finger 1 (figure 3.70) the first piston to the guide element 2.
Turn the handle by hand until it stops, without applying much force.
Place stop 3 on finger.
Open clamp A.
Figure 3.71. Installing the piston in the piston pin pressing device: 1 - piston stop; B - screws; C - boss; D - rod; E - lock nuts
Remove screws B completely.
Note: When installing the piston on the stop, turn it with the boss C facing up (figure 3.71).
Place the piston on stop 1.
Insert rod D.
Tighten screws B until they touch the piston.
Tighten locknuts E.
Tighten rod D to secure the piston.
Figure 3.72. Installing the connecting rod into the fixture: 1 - rod; A - gap; B - emphasis
Insert the connecting rod assembly with the cover (without insert) into the piston and center it using the tool (figure 3.72).
Adjust the position and height of the stop B under the connecting rod so that the gap A is equal to 0.1 mm.
Remove the connecting rod.
Install the connecting rods on the electric heater.
Place a pinch of tin powder into each connecting rod top head.
Heat the connecting rods until the tin melts (approximately 250°C).
Lubricate the piston pins before installing them.
Try to install the piston pin into the piston hole in one motion.
Remove any remaining tin drops.
Figure 3.73. Orientation of the piston with the connecting rod
When assembling the piston with the connecting rod, the "DT" marking must be facing upwards (figure 3.73).
Insert the connecting rod into the piston, with the lock A of the connecting rod bearings oriented in relation to the piston, as shown in Figure 3.73.
Note: When installing on the engine, the bearing lock A must be directed towards the exhaust manifold.
Quickly insert the piston pin until it stops.
Wait a few seconds before removing the connecting rod and piston assembly from the fixture.