To dismantle and assemble (one-piece pistons)

Operation 4-6

To dismantle

Note: Mark the components to ensure that they are returned to the correct cylinder.

1  Remove the piston rings (B5, B6 and B7), see Operation 4-11.

2  Remove the circlips (B1 and B4) that retain the gudgeon pin (B2) and push the gudgeon pin out of the piston

(B3) by hand.

3  Separate the connecting rod from the piston.

To assemble

1  Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.

2  Fit a new circlip (B1) in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in

the groove.

Caution: If the original piston is used, ensure that it is assembled to the correct connecting rod and that it is

used in the original cylinder.

3  With the piston (B3) upside down, put the connecting rod in position. Ensure that the short side of the

connecting rod (A1) is on the same side as the “camside” mark (B) on the piston crown.

4  Lubricate the gudgeon pin and the gudgeon pin bosses in the piston with clean engine lubricating oil.

5  Push in the gudgeon pin (B2) towards the circlip.

6  Fit the other new circlip (B4) in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the

groove.

7  Fit the piston rings, see Operation 4-11.

2

3

1

4

5

1

7

6

A

B

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Peregrine EDi and 1300 Series EDi

To dismantle and assemble (two-piece pistons)

Operation 4-7

To dismantle

Note: Mark the components to ensure that they are returned to the correct cylinder. Mark the piston skirt and

the piston crown to ensure correct assembly.

1  Remove the piston rings, see Operation 4-11.

2  Remove the circlips that retain the gudgeon pin and push the gudgeon pin out of the piston by hand (A).

3  Separate the connecting rod from the piston.

4  Remove the piston skirt (B1) from the piston crown (B2).

To assemble

1  Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.

2  Put the piston skirt (B1) on the piston crown (B2), ensure that the marks made earlier are aligned.

3  Fit a new circlip (A) in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in the

groove.

Caution: If the original piston is used, ensure that it is assembled to the correct connecting rod and that it is

used in the original cylinder.

4  With the piston upside down, put the connecting rod in position. Ensure that the short side of the connecting

rod is on the same side as the “camside” mark on the piston crown.

5  Lubricate the gudgeon pin and the gudgeon pin bosses in the piston with clean engine lubricating oil.

6  Push in the gudgeon pin towards the circlip.

7  Fit the other new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the groove.

8  Fit the piston rings, see Operation 4-11.

1

2

A

B

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Peregrine EDi and 1300 Series EDi

To inspect

Operation 4-8

Special requirements

Special tools

Description

Part number

Piston groove gauges

21825955

1  Check the piston for wear and other damage.

2  Check that the piston rings move freely in their grooves and that the piston rings are not broken.

3  Remove the piston rings, see Operation 4-11.

4  Clean the piston ring grooves and the piston rings.

5  Fit the piston groove gauge 21825955 to the top compression ring groove, measure and record the overall

diameter of the piston and the gauge (A).

6  Fit the piston groove gauge 21825955 to the second compression ring groove, measure and record the

overall diameter of the piston and the gauge (B)

A

B

W049

W049/1

7  Fit a new oil control ring in its groove and check for wear of the ring groove with feeler gauges (C).

8  Measure and record the diameter of the piston skirt (D). Measured at 90° from the gudgeon pin, at a point

27,43 mm (1.08 in) below the oil control ring. Refer to the relevant Data and dimensions for the "Piston rings"

on page 12.

C

D

W050

W087

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Peregrine EDi and 1300 Series EDi

Connecting rod

To inspect

Operation 4-9

1  Check the connecting rod for distortion (A).

Note: The large and small end bores must be square and parallel with each other within the limits of

± 0,127 mm (0.005 in) measured 127 mm (5.0 in) each side of the connecting rod axis on a test mandrel.

2  Check the small end bush for wear or for other damage and renew it, if necessary.

3  Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear. Refer to the

relevant Data and dimensions for the "Gudgeon pins" on page 13.

127mm

127mm

(5in)

(5in)

± 0,127mm

(0.005in)

± 0,127mm

(0.005in)

A

W025

Small end bush

To remove and to fit

Operation 4-10

1  Press out the old bush with a suitable adaptor.

2  Clean the connecting rod bore and remove any sharp edges.

3  Press in the new bush. Ensure that the lubrication hole in the bush is on the same side as, and is aligned

with, the hole in the top of the connecting rod.

4  The connecting rods on all of the engines have a small end that is wedge shaped. After the small end bush

has been fitted, machine the bush to the shape of the small end and remove any sharp edges.

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Peregrine EDi and 1300 Series EDi

Piston rings

To remove and to fit

Operation 4-11

Caution: Only increase the ring gaps enough to ensure that the ends of the rings do not damage the piston.

To remove

1  Remove the piston rings with a suitable ring expander (A1).

To fit

1  Use a suitable ring expander (A1) to fit the piston rings. Keep the rings with their relevant pistons, for correct

assembly.

2  Fit the coil spring and latch pin to the bottom groove in the piston. Fit the oil control ring over the coil spring.

Ensure that the gap in the coil spring and the gap in the latch pin of the coil spring are 180° apart.

1

A

W088

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Peregrine EDi and 1300 Series EDi

To inspect

Operation 4-12

Caution: The coil spring must be fitted to the oil control ring when the gap is measured.

1  Clean all carbon from the top of the cylinder liners.

2  Fit each piston ring (A2) in the top part of the cylinder liner, measure and record the ring gap with feeler

gauges (A1).

1

2

A

W051

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Peregrine EDi and 1300 Series EDi

5

Crankshaft assembly

5

General description

The crankshaft is a steel forging with seven main journals. All the crankshaft journals and the crank pins are

induction hardened.

End-float is controlled by thrust washers that are an integral part of the rear main bearing, and shall be referred

to as thrust bearings in this manual. The area of the bearing surfaces of the seven main bearings is the same.

All the main bearings have location tags.

An integral damper, with a rubber insert is built into the crankshaft pulley. The location of the pulley / damper

assembly is by a key in the crankshaft nose. The assembly is held in position by an interference fit, and by a

retainer plate and three setscrews.The pulley / damper assembly must be heated before it is fitted on the

crankshaft.

The rear oil seal can be renewed without the removal of the flywheel housing.

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Peregrine EDi and 1300 Series EDi

Crankshaft pulley / damper assembly

To remove

Operation 5-1

Special requirements

Special tools

Description

Part number

Crankshaft pulley puller

21825965

Note: Before removing the pulley / damper assembly check for alignment, see Operation 5-2.

1  Drain the lubricating system.

2  Remove the fan drive belt, see Operation 12-7.

3  Release and remove the three setscrews (A) that hold the retainer plate of the pulley / damper assembly.

4  Remove the retainer plate (A).

5  Use the puller 21825965 to remove the pulley / damper assembly (B).

Note: It is recommended that whenever the pulley / damper assembly is removed, the wear sleeve and seals

should be renewed.

A

B

W089

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