B1CJ0JK1 - 206 TU ENGINE

ASSEMBLY CONNECTING RODS - PISTONS

1 - SPECIAL TOOLS

description	reference	reference
[1] base	(-).0139-AZ	-
[2] piston support TU9 piston support TU1 - TU2 - TU3 - TU5	(-).0139-Q (-).0132-D3Y (-).0139-V	4510-TF
[3] gudgeon pin guide : TU9 engine	(-).0139-P	4510-TD
[3]gudgeon pin guide : TU1 - TU2 - TU3 - TU5 engines	(-).0132-D2Z	4510-TE
[4]handle : TU9 engine	(-).0139-N	4510-TC
[4] handle :TU1 - TU2 - TU3 - TU5 engines	(-).0139-B	4510-TC
[5] support for fitting the gudgeon pin	-	4510-TF
[6] piston positioning base	-	6021-T1

2 - PISTONS/CONNECTING RODS ASSEMBLY

Fit the gudgeon pin (1) of the first piston on the guide end piece [3] .

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 [2], position the surface with the boss (C) 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) .

Remove the pin (D) .

Lock the piston .

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 :

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 .

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 .

Marking arrow (DT) on the piston pointing upwards :

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

Marking arrow (DT) on the piston facing downwards :

place the connecting rod in the piston, shell bearing stops (I) to the right in relation to the gudgeon pin

NOTE : in the engine, the shell bearing stops (I) are located on the inlet side .

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 .

2 - 1 - CONNECTING ROD WITH A LUBRICATION HOLE

In the engine, the lubrication hole (K) is on the inlet side .

The lubrication hole (K) is located on the same side as the shell bearing stops (I) .