Connecting Rod: Service and Repair

PISTON AND CONNECTING ROD DISASSEMBLY





1. Check fit between piston and pin.
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.





2. Remove piston rings.
(a) Using a piston ring expander, remove the compression rings.
(b) Remove the 2 side rails and oil ring expander by hand.

NOTE: Arrange the rings in the correct order only.

3. Disconnect connecting rod from piston.





Using Special Service Tool (SST) or equivalent, press out the piston pin from the piston.
Remove the connecting rod.
SST 09221 - 25024 (09221 - 00020, 09221 - 00030, 09221 - 00130, 09221 - 00140, 09221 - 00150)

NOTE:
^ The piston and pin are a matched set.
^ Arrange the pistons, pins, rings, connecting rods and bearings in correct order.

ASSEMBLY
1. Assemble piston and connecting rod.
(a) Coat the piston pin and pin holes of the piston with engine oil.





(b) Align the cavity on the piston with the protrusion on the connecting rod.





(c) Using SST, press in the piston pin.
SST 09221 - 25026 (09221 - 00020, 09221 - 00030, 09221 -00130, 09221 -00140, 09221 -00150) or equivalents.





(d) After installing the piston pin, check that when the connecting rod is aligned with the center of the piston the space between the piston and each end of the piston pin are equal on the left and right sides.

NOTE: If the piston pin is off-center due to insufficient insertion pressure on the piston pin, place a washer at the position indicated by the DOT in the illustration for (c). Then, while checking that the space is equal at the ends of the piston pin on the left and right sides, press in the washer.

2. Install piston rings.
(a) Install the oil ring expander and 2 side rails by hand.





(b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code Mark:
No. 1: 1R
No. 2: 2R





(c) Position the piston rings so that the ring ends are as shown.

CAUTION: Do not align the end gaps.

3. Install bearings.
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.





(b) Install the bearings in the connecting rod and connecting rod cap.