CONNECTING ROD CAP
Keep the bearings in order with their
corresponding connecting rods (according to cylinder numbers) for
proper reassembly. |
1. |
Remove the connecting rod cap bolts, then
remove the caps and the big end lower bearing mark for
reassembly. |
2. |
Push each piston connecting rod assembly
toward the top of the cylinder.

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DISASSEMBLY AND REASSEMLY OF THE PISTON
PIN
1. |
Using the special tools 09234 - 33001 and
09234 - 3002, disassemble and reassemble the piston and connecting
rod.

|
2. |
The piston pin is a press fit in the rod
little end, and the piston floats on the
pin. |
3. |
The tool consists of a support fixture with
fork inserts, guides, adapters, an installer and a remover. The
piston is supported in the support fixture while the pin is being
installed or removed. Guides help position the pin as it is
installed or removed, while the rod is supported by fork
inserts. |
4. |
To remove the pin from the piston, place the
piston in the support fixture with the rod resting on the fork
inserts. Pass the remover tool through the top of the support
fixture and use it to press out the pin.

|
5. |
To install a new pin, the proper fork inserts
must be in place to support the
rod. |
6. |
Position the rod inside the piston. Insert the
proper pin guide through one side of the piston and through the rod.
Hand tap the pin guide so it is held by the piston. Insert the new
pin into the piston from the other side and set the assembly into
the support fixture with the pin guide facing down.
The pin guide should be centered on the
connecting rod through the piston. If assembled correctly, the
pin guide will sit exactly under the center of the hole in the
tool's arch, and rest evenly on the fork inserts. If the wrong
size pin guide is used, the piston and pin will not up with
the support fixture.

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7. |
Insert the installer tool through the hole in
the arch of the support fixture and use an hydraulic press to force
the piston pin through the rod little end. Continue pressing until
the pin guide falls free and the installer tool seats against the
top of the arch.
Do not exceed 1250 ± 500 kg (2765 ± 1100
lb) of force when the installing tool seats angainst the top
of the
arch. | |
Pistons and Piston Pins
1. |
Check each piston for scuffing, scoring, wear
and other defects. Replace any piston that is
defective. |
2. |
Check each piston ring for breakage, damage
and abnormal wear. Replace the defective rings. When the piston
requires replacement, its rings should also be
replaced. |
3. |
Check that the piston pin fits in the piston
pin hole. Replace any piston and pin assembly that is defective. The
piston pin must be pressed smoothly by hand into the pin hole (at
room temperature). |
Piston Rings
1. |
Measure the piston ring side clearance. If the
measured value exceeds the service limit, insert a new ring in the
ring groove to measure the side clearance. If the clearance still
exceeds the service limit, replace the piston and rings together. If
it is less than the service limit, replace only the piston
rings.
Piston ring
side clearance
No.1 : 0.04 ~ 0.08mm (0.0016 ~
0.0031in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~
0.0028in.)
[Limit]
No.1 : 0.1 mm (0.004 in.)
No.1 : 0.1 mm (0.004
in.)
| |
2. |
To measure the piston ring end gap, insert a
piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a
piston. Measure the gap with a feeler gauge. If the gap exceeds the
service limit, replace the piston ring.
Piston ring
end gap
[Standard dimensions]
No.1 : 0.20 ~ 0.35mm (0.0079 ~
0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~
0.0205in.)
[Limit]
No.1, No.2 : 0.8mm
(0.031in.)
Oil ring side rail : 1.0mm
(0.039in)
|
When replacing the ring without correcting the
cylinder bore, check the gap with the ring situated at the lower
part of cylinder that is less worn out.
Piston ring service size and mark
Standard
|
None
|
0.25mm
(0.010in.) O.S 0.50mm (0.020in.)
O.S
|
25 50
|
The mark can be found on the upper side
of the ring next to the end.

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Connecting Rods
1. |
When the connecting rod cap is installed, make
sure that the cylinder numbers, marked on rod end cap at
disassembly, match. When a new connecting rod is installed, make
sure that the notches holding the bearing in placeare on the same
side. |
2. |
Replace the connecting rod if it is damaged at
either end of the thrust faces. If it has a stratified wear, or if
the surface of the inside diameter of the small end is severely
rough, replace the rod.

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1. |
Install the spacer.


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2. |
Install the upper side rail. To install the
side rail, first put one end of the side rail between the piston
ring groove and spacer, hold it firmly, and press down with finger
on the portion to be inserted into the groove (as
illustrated).
Do not use a piston ring expander when
installing the side
rail. | |
3. |
Install the lower side rail by the same
procedure described in Step 2.

|
4. |
Apply engine oil around the piston and piston
grooves. |
5. |
Using a piston ring expander, install the No.2
piston ring. |
6. |
Install the No. 1 piston ring.

|
7. |
Position each piston ring end gap as far away
from its neighboring gaps as possible. Make sure that the gaps are
not positioned in the thrust and pin
directions. |
8. |
Hold the piston rings firmly with a piston
ring compressor as they are inserted into cylinder.

|
9. |
Install the upper main bearings in the
cylinder block. |
10. |
Install the lower main bearings in the main
bearing caps.
Install the bearing so it matches the
oil hole in the block.

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11. |
Install the thrust washers in the No. 3 main
bearing cap with the oil grooves facing outward.

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12. |
Make sure that the front mark of the piston
and the front mark (identification mark) of the connecting rod are
directed toward the front of the
engine. |
13. |
When the connecting rod cap is installed, make
sure that any cylinder numbers placed on the rod and cap at
disassembly match. |
14. |
When a new connecting rod is installed, make
sure that the notches for holding the bearing in place are on the
same side. |
15. |
When assembling, bolts should be fastened
using the plastic angle technique as follows.
(1) |
Apply oil to the threads and matching
areas. |
(2) |
Tighten the connecting rod
bolt.
Tightening torque
Connecting rod bolt :
16 ~ 20Nm (160~200kg.cm,
12~15lb.ft) + (90°~94°)
|
After removing the connecting rod
bolt, do not use it again.
When using a new bolt, do not
tighten the bolt more than 3 times.

| | |
16. |
Check the connecting rod side
clearance.
Connecting rod
side clearance
Standard : 0.10 ~ 0.25mm (0.0039 ~
0.0098in.)
Limit : 0.4mm
(0.0157in.)
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