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To facilitate reassembly, mark the side face of the connecting rod big end with the corresponding
cylinder number.
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The special tool Piston pin setting tool (MD998780) consists of the parts illustrated.
The special tool Guide D (MB991659) is also used for removal.
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1.Insert the Push rod (special tool) into the piston, from the piston side with the front
mark on the piston top face. Install the Guide D on the other side.
2.Install the piston and connecting rod assembly with the tools onto the Piston pin
setting base (special tool), ensuing that the piston front mark faces upwards.
3.Using a press, remove the piston pin.
| note |
With the piston pin removed, keep the pin, piston and connecting rod of the same cylinder
together.
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1.Insert the special tool Push rod into the piston pin, and install Guide A.
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2.Assemble the piston and the connecting rod together, ensuring that their front marks are
aligned with each other.
3.Apply engine oil onto the periphery of the piston pin.
4.Insert the piston pin assembled in step 1 above into the piston pin boss. Guide A
end of the piston pin should be inserted first into the front mark end of the boss.
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5.Insert Guide B into Guide A with having 2.25 mm of the clearance "L" between Guide A and
B.
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6.Install the piston and connecting rod assembly with the tools onto the Piston setting
base (special tool), ensuring that the piston front mark faces upwards.
7.Using a press, press fit the piston pin. If the force required to press fit the piston
pin is less than the standard value, replace the piston pin (piston assembly) or the connecting rod,
or both.
Standard value: 5,000 - 11,000 N
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1.Install the oil ring spacer first into the piston ring groove, followed by the upper
side rail and then the lower side rail.
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2.
| caution |
Do not use a ring expander on side rails as they may
break when the gap is opened.
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Side rails can be installed easily by first inserting one end of the rail into the piston
groove, then pressing the rail into place with finger.
3.With the side rails installed onto the piston, check that they can be rotated smoothly
in both directions.
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4.The gaps of the side rails and spacer should be located as illustrated.
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Use a piston ring expander to install the No. 1 and No. 2 piston rings. The ring identification
mark should face upwards.
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Identification mark
No. 1 ring: None
No. 2 ring: 2R
| note |
Each of the available piston rings has a size mark as follows:
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Size
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Size mark
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Standard
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No. 1 ring
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No mark
(Yellow paint on periphery)
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No. 2 ring
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No mark
(Yellow paint on periphery)
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1.Apply engine oil sufficiently onto the piston periphery, the piston rings and the
oil ring.
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2.Align the gaps of the piston rings and the oil ring (side rails, spacer) as illustrated.
3.Insert the piston and connecting rod assembly from above the cylinder block and through
the cylinder bore, ensuring that the front mark on the piston top faces the camshaft sprocket.
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4.
| caution |
Do not try to strike hard on the assembly to fit it in
place as this will break the piston rings.
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While firmly holding the piston rings with a ring band, insert the piston and connecting
rod assembly into place.
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1.The connecting rod bearing has the identification mark at the illustrated position. Bearings
should be selected based on the following table.
| note |
Service parts is black or 2 only.
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Connecting rod bearing identification mark
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Upper bearing
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Lower bearing
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Blue or 1
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Red or 3
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Red or 3
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Blue or 1
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Black or 2
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Black or 2
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Example: If a blue or 1 upper bearing is selected, the lower bearing must
be red or 3.
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2.Measure the illustrated location. The error should be within 0.5 mm.
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1.Install the correct bearing cap onto the corresponding connecting rod, based on the marking
placed during disassembly.
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2.Ensure that the thrust clearance of the connecting rod big end is to specification.
Standard value: 0.10 - 0.35 mm
Limit: 0.4 mm
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1.Inspect all reused connecting rod bolts according to the following procedure.
(1)
Measure the outside diameter at 15 mm and 30 mm from the head of the connecting rod
bolts shown in Figure respectively.
(2)
When the difference between the outside diameters (measured at 15 mm and 30 mm) exceeds
the standard value, replace the connecting rod bolts.
Standard value: 0 - 0.1 mm
2.Apply engine oil to the threaded portion and seating face of the bolt.
3.To correctly install the cap, loosely install the bolts with fingers.
4.Alternately, tighten the bolts in several steps to the specified torque of 14.7 ± 2.0
N·m.
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5.Put a paint mark on the bolt head as illustrated.
6.Put another paint mark on the bolt head at 90 to 94° in the tightening direction
from the first paint mark.
7.
| caution |
- When the tightening
angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot
be secured.
- When the tightening angle is larger than the specified tightening angle, remove
the bolt to start from the beginning again according to the procedure.
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Tighten the bolt 90 to 94°. The paint mark on the connecting rod should be aligned
with the paint mark on the bolt.
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