Procedures

1028H11 PISTON CONNECTING ROD SET - R R

Engines: 2.0 16V, 2.8 JTD 8V

Engines: 2.0 16V

Removing

Op. 1048A31 RIGID PIPE CONNECTING AIR CLEANER TO INLET MANIFOLD RIGID PIPE R R Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1072C10 Op. 1092C11 POWER STEERING PUMP DRIVE BELT - R R FOR VERSIONS WITH AIR CONDITIONER Op. 1092B40 AIR CONDITIONER COMPRESSOR/ALTERNATOR DRIVE BELT - R + R See in Op. 1092A12 See in Op. 1032D12 See in Op. 1032B14 See in Op. 1016C11 Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R See in Op. 1020A30 Op. 1020A26 CRANKCASE SUMP - R R CLEAN MATING SURFACES AND APPLY SEALANT FOR VEHICLE WITH AIR CONDITIONER See in Op. 1084B281. Undo the bolts and remove the connecting rod caps complete with 2nd and 3rd cylinder lower connecting rod half-bearings.

Engines: 2.0 16V

- Lower the vehicle.1. Withdraw and remove 2nd and 3rd cylinder pistons (1a) with connecting rods (1b) and upper connecting rod half bearings.

Engines: 2.0 16V

- Turn the crankshaft and proceed in the same way to remove the 1st and 4th cylinder pistons and connecting rods.

Engines: 2.0 16V

Refitting

Removing

- Fit the 1st and 4th pistons with connecting rods and connecting rod upper bearing halves using a suitable installing tool to compress the piston rings.

	Description	Code	Function
.	Fitting tool	1.860.700.000	Fitting tool

- Fit the connecting rod caps complete with the half-bearings for cylinders no. 1 and 4 and secure them without tightening the bolts to torque.- Proceed in the same way to fit the 2nd and 3rd cylinder pistons and connecting rods. See in Op. 1084B28 Op. 1020A26 CRANKCASE SUMP - R R CLEAN MATING SURFACES AND APPLY SEALANT FOR VEHICLE WITH AIR CONDITIONER See in Op. 1020A30 Op. 1024B54 ENGINE FLYWHEEL PROTECTION R R See in Op. 1016C11 See in Op. 1032B14 See in Op. 1032D12 See in Op. 1092A12 Op. 1092B40 AIR CONDITIONER COMPRESSOR/ALTERNATOR DRIVE BELT - R + R Op. 1092C11 POWER STEERING PUMP DRIVE BELT - R R FOR VERSIONS WITH AIR CONDITIONER See in Op. 1072C10 Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 1048A31 RIGID PIPE CONNECTING AIR CLEANER TO INLET MANIFOLD RIGID PIPE R R Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP Op. 0010T21 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY

Engines: 2.8 JTD 8V

Removing

Refitting

See in Op. 1088B10 Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE See in Op. 1048B14 See in Op. 1048B22 See in Op. 1016A10 See in Op. 1060G22 Op. 7055B54 UNDER-ENGINE GUARD - R R Op. 1080B62 CATALYTIC CONVERTER - R + R See in Op. 1048A10 See in Op. 1060E10 See in Op. 1048B10 See in Op. 1016C11- Fit the timing side flexible engine block by screwing in the retaining bolts without tightening.- Remote the tool positioned beneath the sump for supporting the power unit.

	Description	Code	Function
.	Crossmember	1.870.735.000	Lower engine mounting beam

See in Op. 1020A30 Op. 1020A12 CRANKCASE OIL SUMP - VEHICLES WITH AIR CONDITIONER - R + R AND REPLACE GASKET See in Op. 1084B281. Undo the bolts and remove the connecting rod caps complete with 2nd and 3rd cylinder lower connecting rod half-bearings.

Engines: 2.8 JTD 8V

- Lower the vehicle.1. Withdraw and remove 2nd and 3rd cylinder pistons (1a) with connecting rods (1b) and upper connecting rod half bearings.

Engines: 2.8 JTD 8V

- Turn the crankshaft and proceed in the same way to remove the 1st and 4th cylinder pistons and connecting rods.

Engines: 2.8 JTD 8V

Refitting

Removing

- Fit the 1st and 4th pistons with connecting rods and connecting rod upper bearing halves using a suitable installing tool to compress the piston rings.

	Description	Code	Function
.	Fitting tool	1.860.700.000	Fitting tool

- Fit the connecting rod caps complete with 1st and 4th cylinder lower bearing halves and secure by tightening the bolts to the recommended torque. Carry out angular tightening separately and using an angle wrench for tightening.

	Description	Code	Function
.	Torque wrench	1.860.942.000	Connecting rod cap bolt angular tightening

	Value - daNm	Fastening	Component	Ø
.	4,5 - 5,5 + 63°	Bolt	CONNECTING ROD CAP FASTENERS	M12

- Proceed in the same way to fit the 2nd and 3rd cylinder pistons and connecting rods. See in Op. 1084B28 Op. 1020A12 CRANKCASE OIL SUMP - VEHICLES WITH AIR CONDITIONER - R + R AND REPLACE GASKET See in Op. 1020A30- Remove the tool positioned beneath the sump for supporting the power unit.

	Description	Code	Function
.	Crossmember	1.870.735.000	Lower engine mounting beam

- Undo the retaining bolts and remove the timing side flexible engine block. See in Op. 1016C11 See in Op. 1032B14 See in Op. 1048B10 See in Op. 1060E10 See in Op. 1048A10 Op. 1080B62 CATALYTIC CONVERTER - R + R Op. 7055B54 UNDER-ENGINE GUARD - R R See in Op. 1060G22 See in Op. 1048B22 See in Op. 1048B14 Op. 0010T84 COOLANT FOR AIR CONDITIONING SYSTEM DEHYDRATE AND RECHARGE See in Op. 1088B10 Op. 0010T20 COOLANT CHECK DENSITY AND TOP UP IF NECESSARY Op. 0010T11 ENGINE OIL CHECK LEVEL AND TOP UP