Removal and Installation
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 snap rings.
CAUTION:
The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure to heat the piston before pulling out the piston pin. Use care since the piston is hot after heating.
2. Heat the piston to approximately 70° C (158° F) and pull out the piston pin.
INSTALLATION SERVICE POINTS
]]A[[
PISTON PIN INSTALLATION
1. When replacing the piston, note the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table.
NOTE:
The piston size mark shows on the top of the piston.
2. Set the snap ring into one side of the piston pin hole.
CAUTION:
Apply an ample coat of engine oil to the periphery of the piston pin and the hole of the connecting rod small end. The clearance between the piston and the piston pin is a tight fit at room temperature. Therefore, be sure to heat the piston before inserting the piston pin. Use care since the piston is hot after heating.
3. Heat the piston to approximately 70° C (158° F).
4. With the front mark of the connecting rod and that of the piston located on the same side, insert the piston pin.
5. Set the snap ring into the other side of the piston pin hole.
6. Check that the piston moves smoothly.
]]B[[
OIL RING INSTALLATION
1. Fit the oil ring spacer into the piston ring groove.
NOTE:
The side rails and spacer may be installed in either direction.
CAUTION:
Do not use any piston ring expander when installing the side rail. It will break the side rail.
2. Install the upper side rail by hand.
To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position. See illustration.
3. Install the lower side rail in the same procedure as described in step 2.
4. Make sure that the side rails move smoothly in both directions.
]]C[[
PISTON RING NUMBER 2 /
PISTON RING NUMBER 1 INSTALLATION
1. To prevent wrong installation, check the identification mark of each piston ring.
The identification mark is stamped near the ring gap.
Identification mark
Number 1 ring: 1T
Number 2 ring: 2T
NOTE:
Size marks on piston rings are as follows.
2.
3. Using a piston ring expander, fit the number 2 piston ring into the number 2 groove of piston.
NOTE:
Install the piston rings with their identification mark facing up, to the piston crown side.
4. Install the number 1 piston ring in the same manner as step 2.
]]D[[
CONNECTING ROD BEARING INSTALLATION
1. Measure the crankshaft pin diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification color of its pins are painted at the positions shown in the illustration.
2. From the above table, select a bearing whose size is appropriate for the crankshaft pin outside the diameter.
3. Install the selected bearing in the big end and in the cap of the connecting rod.
]]E[[
PISTON AND CONNECTING ROD INSTALLATION
1. Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.
4. Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing belt side.
5. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
]]F[[
CONNECTING ROD CAP INSTALLATION
1. Verifying the mark made during disassembly, install the bearing cap to the connecting rod. If the connecting rod is new with no index mark, make sure that the bearing locking notches are on the same side as shown.
2. Make sure that the connecting rod big end side clearance meets the specification.
Standard value: 0.05 - 0.25 mm (0.002 - 0.009 inch)
Limit: 0.4 mm (0.02 inch)
]]G[[
CONNECTING ROD CAP NUT INSTALLATION
1. The connecting rod bolts should be examined before reuse. If the bolt threads are damaged, the bolt should be replaced.
Hand-thread the nut to 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 threaded portion and bearing surface of the nut.
3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to a torque of 27 ± 2 Nm (20 ± 1 ft-lb) to install the cap properly.
5. Make a paint mark on the head of each nut.
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.
6. Make a paint mark on the bolt end at a position 90 to 94 degrees from the paint mark made on the nut in the direction of tightening the nut.
7. Turn the nut another 90 to 94 degrees and make sure that the paint marks on the nut and bolt are aligned.