Magentis and Optima repair since 2000 of release
1. Engines
1.1. Engines of 2,0 l of DOHC
1.1.1. Specifications
1.1.2. Compression check
1.1.3. Gear belt
1.1.4. Check and adjustment of a tension of poliklinovy belts
1.1.5. Adjustment of a tension of a belt of a drive of the generator
1.1.6. Adjustment of a tension of a belt of a drive of the amplifier of a wheel and conditioner
1.1.7. Check of hydraulic jacks of gaps of valves
1.1.8. Head of the block of cylinders and valve
1.1.9. Engine support
1.1.10. Removal and engine and transmission installation
1.1.11. Camshafts and yokes
1.1.12. Forward cover, oil pump and balancing shaft
1.1.13. Piston and rod
1.1.14. Cranked shaft and flywheel
1.1.15. Block of cylinders
1.1.16. The air filter (except V6)
1.1.17. Inlet collector
1.1.18. Final collector
1.1.19. Exhaust silencers
1.1.20. Search and elimination of malfunctions
1.2. Engines of V6 2,5 l
2. Greasing system
3. Cooling system
4. Control and decrease in toxicity
5. Fuel system
6. Ignition system
7. Coupling
8. Transmission
9. Power shafts, axes
10. Suspension bracket
11. Steering
12. Brake system
13. Body
14. Central air
15. Electric equipment
16. Electric circuits
 










1-1-13-porshen-i-shatun.html

1.1.13. Piston and rod

Removal

Rod cover

 PERFORMANCE ORDER

Hold covers of rods with the corresponding rods for the correct repeated installation them in engine cylinders.

1. Unscrew nuts and uncover a rod and the bottom loose leaf of the shatunny bearing. For protection of necks of a cranked shaft dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.

2. Wooden whetstone or the hammer handle вытолкните the piston with a rod from the cylinder.

Removal and installation of a piston finger

 PERFORMANCE ORDER

1. For dismantling and repeated assembly of the piston and a rod it is necessary to use special tools 09234-33001.

2. Establish universal support in a clip between a rod and the piston.

3. Insert a stripper through an opening in a clip arch.

Insert a clip with the piston, a rod and a stripper under ползун the press.

4. A stripper squeeze out a piston finger from the piston.

5. Establish directing pins via the piston in a rod, and a piston finger establish on the other side of the piston.

Directing pins define the provision of a rod in the piston. After installation of the piston, a rod, a piston finger and the adaptation for installation of a piston finger in the inserts directing pins also define their situation in a clip. If directing pins too small, the piston does not settle down on the center in the adaptation and the clip and / or the adaptation can be damaged.

6. Establish the piston assembled on a clip thus directing a pin supports a rod in a piston finger. Be convinced that the piston approaches on a clip while the directing pin will not contact with a vilochny insert.
7. Check correctness of a relative positioning of the piston and a rod and, rotating a nut with a nakatka, fix the numbered plug on a shaft.

8. Insert a shaft through an opening in a clip arch. Press a piston finger into a rod while the plug on a shaft will not contact with the top part of an arch of the clip, thus directing pin should drop out of the piston.

The effort of a press fitting of a piston finger should not exceed 22500 N.

Check

Piston and piston fingers

 PERFORMANCE ORDER

1. Check an external surface of the piston on absence of damages, development or non-uniform wear. If necessary, replace the piston.
2. Check each piston ring on absence of damages and non-uniform wear. If necessary, replace piston rings. At replacement of the piston it is also necessary to replace piston rings.
3. Check a piston finger, inserting it into a piston opening. The piston finger should enter smoothly into the piston by pressing it a hand (at room temperature).

Piston rings

 PERFORMANCE ORDER

1. Insert a new piston ring into a flute of the piston and shchupy measure a gap between a piston ring and a flute wall. If the gap exceeds maximum permissible value, replace the piston.

Gap between a piston ring and a flute in the piston:

  • First kompressionny ring: 0,03–0,07 mm
  • Second kompressionny ring: 0,02–0,06 mm
  • Maximum permissible gap: 0,1 mm

2. Measure a gap in the lock of piston rings, having manually inserted a piston ring into the engine cylinder. The bottom of the piston push a piston ring in the lower part of the cylinder. By Shchup measure a gap in the lock of a piston ring.

Gap in locks of piston rings:

  • First kompressionny ring: 0,25–0,35 mm
  • Second kompressionny ring: 0,40–0,55 mm
  • Maslosjemnoye ring: 0,10–0,40 mm
  • Maximum permissible gap: 1,0 mm
  • First and second kompressionny rings: 0,8 mm
  • Maslosjemnoye ring: 1,0 mm

Rods

 PERFORMANCE ORDER

1. At installation be convinced that the rod and a cover of a rod correspond to cylinder number in which they are established. At installation of a new rod make sure that the labels defining its situation, are from the same party as a label on other rods.

2. Replace a rod if there are damages on both basic surfaces. Also replace a rod if there is a wear or damage of the surface interfaced to a piston finger.

Installation

 PERFORMANCE ORDER

1. Establish a broad ring.

2. Establish the top lateral directing. To establish lateral directing, at first place one end of a lateral flute of a piston ring directing between a wall and a broad ring, press it then, pressing on perimeter, establish it in a piston flute.

Do not use пассатижи for a release of piston rings at installation of the lateral directing.

3. Similarly establish the bottom lateral directing.
4. To Passatizhami for a release of piston rings establish a kompressionny ring No. 2.

5. To Passatizhami for a release of piston rings establish a kompressionny ring No. 1.

6. Apply a thin film engine oil on the piston and piston rings.

7. Arrange locks of piston rings, as is shown in drawing.

8. The special adaptation compress piston rings on the piston.
9. Establish the piston with piston rings over the first cylinder, thus the label on the piston should be directed to a forward part of the block of cylinders.
10. The handle of a hammer press the piston into the cylinder so that the bottom head of a rod was established on a neck of a cranked shaft.
11. Establish the shatunny loose leaf in a rod cover.

12. Establish a cover of a rod and fix nuts. Be convinced that a cylinder label on a rod and a cover of a rod are on the one hand.

Inhaling moment: 32–35 N • m + to tighten on a corner 90 °–94 °

13. Shchup inserted between a rod and cranked shaft, measure a lateral gap of a rod.

  • Nominal lateral gap of a rod: 0,10–0,25 mm
  • Maximum permissible gap: 0,40 mm

«on a step back
1.1.12. Forward cover, oil pump and balancing shaft
on the following page»
1.1.14. Cranked shaft and flywheel