Piston and Connecting Rod

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS
[[A]] CONNECTING ROD CAP REMOVAL





1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.

[[B]] PISTON PIN REMOVAL








1. Remove the stop screw from the base.





2. Select the correct piston support for your application. Fit the piston support onto the base. Place the base on press support blocks.
3. Insert the press pin through the piston pin hole. Select the correct connecting rod guide pin. Thread the guide pin onto the threaded portion of the press pin.
4. Position the piston assembly on the piston support in the press. With the press pin up as shown in Figure 4, insert the guide pin through the hole in the piston and through the hole in the piston support.
5. Press the piston pin out of the assembly.

IMPORTANT: To avoid piston damage,
^ The piston support must seat squarely against the piston.
^ Verify that the piston pin will slide through the hole in the piston support.

6. Remove the piston pin from the press pin.

INSTALLATION SERVICE POINTS
]]A[[ PISTON PIN INSTALLATION





1. Thread the stop screw and lock nut assembly into the base. Fit the correct piston support on top of the base. Insert the press pin, threaded end up, into the hole in the piston support until the press pin touches the stop screw.
2. Using the markings on the press pin, adjust the stop screw to the depth as shown.
Depth: Refer to the operating instructions on the special tool.
3. Place the base on press support blocks.





4. Slide the piston pin over the threaded end of the press pin, and thread the correct guide pin up against it.
5. Coat the piston pin with oil, and with the connecting rod held in position, slide the guide pin through the piston and connecting rod.
6. Press the piston pin through the connecting rod until the guide pin contacts the stop screw.
7. Remove the piston assembly from the base. Remove the guide pin and press pin from the assembly.

IMPORTANT: Due to production tolerance variations, it is necessary to visually inspect the piston pin depth after installation to verify that the piston pin is centered. Adjust if necessary.





8. Check that the piston moves smoothly.

]]B[[ OIL RING INSTALLATION








1. Fit the oil ring spacer into the piston ring groove. Then fit the upper and lower side rails.





NOTE:
^ The spacer and side rails may be fitted in either direction. No distinction is made between top and bottom.
^ Spacer and side rail sizes are color-coded as follows:

To install a side rail, fit one end of the rail into the groove, then press the rest of the rail into position by hand as shown.

CAUTION: Do not fit side rails using a piston ring expander since they may break.

2. After installing the side rails, check that they more smoothly in both directions.

]]C[[ PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION





Using a ring expander, fit ring No. 2 and ring No. 1 with their identification marks facing upward (on the piston crown side).
Identification mark:
No. 1 ring: T
No. 2 ring: T2








NOTE: The piston ring is stamped with the following size mark.

]]D[[ PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION
1. Apply oil to the piston, piston ring, and oil ring.





2. Align the gaps of the piston rings and oil rings (side rails and spacer) as shown.
3. With the piston crown's front arrow mark pointing toward the timing belt side, press the piston and connecting rod assembly into the cylinder from the top of the cylinder.





4. Compress the piston rings tightly with a suitable ring compression tool, then press the piston and connecting rod fully into the cylinder. Do not strike the piston hard since the piston rings may break and the crank pin may be nicked.

]]E[[ CONNECTING ROD BEARING INSTALLATION











When replacing the bearings and/or crankshaft, read off the identification mark on the crankshaft (as illustrated), and select a bearing according to the following table.

]]F[[ CONNECTING ROD CAP INSTALLATION





Aligning the marks made during disassembly, fit the bearing cap onto the connecting rod. If the connecting rod is new and has no index mark, ensure that the bearing locking notches are both on the same side.





Check that the connecting rod big end side clearance confirms with specification.
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit: 0.4 mm (0.016 inch)

]]G[[ CONNECTING ROD CAP NUT TIGHTENING
1. Since the connecting rod cap bolts and nuts are torqued using the plastic area tightening method, the bolts should be examined before reuse. If the bolt threads are "necked down", the bolt should be replaced. Necking can be checked by running a nut with your fingers the full length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced.
2. Before installation of each nut, apply engine oil to the nut.
3. Install each nut to the bolt and finger-tighten it. Then tighten the nuts alternately to install the cap properly.
4. Tighten the nuts to a torque of 20 Nm (15 ft. lbs.).
5. Make a paint mark on the head of each nut.





6. Make a paint mark on the bolt end at the position 90 degree angle to 100 degree angle from the paint mark made on the nut in the direction of tightening the nut.
7. Give a 90 degree angle to 100 degree angle turn to the nut and make sure that the paint mark on the nut and that on the bolt are in alignment.

CAUTION
^ If the nut is turned less than 90 degree angle, proper fastening performance may not be expected. When tightening the nut, therefore, be careful to give a sufficient turn to it.
^ If the nut is over tightened (exceeding 100 degree angle), loosen the nut completely and then retighten it by repeating the tightening procedure from step (1).

INSPECTION
PISTON RING





1. Check for side clearance.
If the limit is exceeded, replace the ring or piston, or both.
Standard value:
No. 1: 0.03 - 0.07 mm (0.0012 - 0.0028 inch)
No. 2: 0.02 - 0.06 mm (0.0008 - 0.0024 inch)
Limit:
No. 1: 0.1 mm (0.0039 inch)
No. 2: 0.1 mm (0.0039 inch)





2. Install the piston ring into the cylinder bore. Force the ring down with a piston, the piston crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge.
If the end gap is excessive, replace the piston ring.
Standard value:
No. 1: 0.15 - 0.30 mm (0.0059 - 0.0118 inch)
No. 2: 0.40 - 0.55 mm (0.0157 - 0.0217 inch)
Oil: 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
Limit:
No. 1, No. 2: 0.8 mm (0.031 inch)
Oil: 1.0 mm (0.039 inch)

CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGING MATERIAL METHOD)
1. Remove oil from the crankshaft pin and connecting rod bearing.





2. Cut the plastic gauging material to the same length as the width of bearing and place it on crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten the nuts to the specified torque.
4. Carefully remove the connecting rod cap.
5. Measure the width of the plastic gauging material at its widest part by using a scale printed on its package.
Standard value: 0.02 - 0.05 mm (0.0008 - 0.0020 inch)
Limit: 0.1 mm (0.004 inch)