Removing Pistons - Cylinders 1-3

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Risk of bruising
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Information

The specified positions are for removing and installing components on the engine assembly support with the engine in a vertical position.

Information

Turn special tool > 9764 - disassembly tool only clockwise for removing the piston-pin circlips.
Always hold the tool firmly with one hand when using it.
Replace removed piston-pin circlips.

Information

The circlip will engage in the tool with an audible click.

Mark installation position of the pistons -1 to 3- with a touch up stick.

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Pistons 1 to 3
Unscrew screw plug -1- .

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Screw plug
Turn the crankshaft and vibration damper to position -D- bottom dead centre -UT 1/4- and lock at this position using > 9595/1 - locating pin-1- .

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Vibration damper
> 9764 - Disassembly tool with groove -arrow- at approx. 9 o'clock position must be pushed through the assembly bore.

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Groove position for circlip hook
> 9764 - Disassembly tool must be positioned on the circlip -1- . Then, carefully turn it to the left and right until you feel a certain amount of resistance on the hook.

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Circlip
> 9764 - Disassembly tool-1- must be held securely while turning the pipe clockwise until you feel a certain amount of resistance.
The screw -2- moves horizontally to the left from -Position A- in the guide groove.

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Tool 9764 at position A
Hold the pipe firmly and keep it pressed slightly against the piston in a clockwise direction -arrow 2- . > 9764 - Disassembly tool-1- must now be pulled slowly until the screw is at position -B- .

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Tool 9764 at position B
> 9764 - Disassembly tool-1- must be held securely while turning the pipe clockwise -arrow 2- until you feel a certain amount of resistance.

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Tool 9764 at stop ahead of position C
Hold the pipe firmly and press it slightly against the piston. > 9764 - Disassembly tool-1- must now be pulled slowly with spring force until the screw is at position -C- .

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Tool 9764 at position C
> 9764 - Disassembly tool with circlip -1- must now be pulled slowly out of the crankcase -arrow- . Dispose of the circlip.

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9764 Disassembly tool
> 9777 - Disassembly tool must be pushed as far as it will go into the piston pin.
Hold middle knob -1- securely and turn the knob -2- anti-clockwise as far as it will go -arrow- .

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Piston pin on disassembly tool 9777

Pull out piston pin -1- using interchangeable insert -2- .

Inset shows the tensioned piston pin.

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Piston pin

Turn the rear knob clockwise until the piston pin can be removed.
Push the > 9783 - assembly aid into the cylinder bore from the oil pan side and knock out the piston (by tapping lightly on the grip of the > 9783 - assembly aid with the ball of your hand.

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Assembly aid 9795 for connecting rods

Match the pistons to the correct piston pin immediately after removal and place them where they will not be confused.

Push the > 9795 - assembly aid-1- onto the connecting rod.
Turn the crankshaft on the vibration damper to position -F- bottom dead centre -UT2/5- and lock at this position using > 9595/1 - location g pin-1- .

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Vibration damper
Repeat steps 5 to 13 for removing piston 2.
Turn the crankshaft on the vibration damper to position -B - bottom dead centre -UT3/6- and lock at this position using > 9595/1 - location g pin-1- .

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Vibration damper
Repeat steps 5 to 13 for removing piston 3.
If the pistons are to be re-installed:
Check piston for wear.