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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 that order according to the
cylinder number.
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1.Not to damage the crank
pin, attach a special tool Bolt guide (MB992010), to the
connecting
rod bolt.
2.Remove the piston and connecting rod
assembly from the cylinder block.
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The special tool Piston pin setting
tool (MD998780), consists of the elements shown in
the drawing.
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1.Insert the tool element,
Push rod, into the piston from the front mark side, then
attach
the element, Guide C, to the push rod.
2.Place the
piston and connecting rod assembly on the element, Base,
with the front
mark facing up.
3.Use a press to remove the piston
pin.
| note |
Keep the disassembled pistons,
piston pins and connecting rods cylinder by
cylinder.
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1.When replacing a piston,
check the cylinder bore size mark stamped at the indicated
location
on the cylinder block and select an appropriate replacement
piston using the following table.
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Cylinder bore size
mark
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Piston size
mark
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I
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A
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II
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No mark
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III
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C
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| note |
The piston size mark is
located on the piston top surface.
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2.Insert the tool element, Push rod, into the
piston pin and attach the element, Guide
A, to the push rod end.
3.Assemble the connecting
rod with the piston with their front marks facing in the
same
direction.
4.Apply engine oil to the outside
surface of the piston pin.
5.Insert the assembly
of piston pin, Push rod, and Guide A (put together in step
4.)
into the piston holes from the front mark side.
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6.Insert the tool element,
Guide B, into the tool element, Guide A, with having 2.75 mm
of the clearance "L" between the tool element, Guide A and
B.
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7.Place the piston and
connecting rod assembly onto the element, Piston setting
base, with
the front marks facing up.
8.Install the piston
pin using a press. If the required press force is less than
the
standard value, replace the piston and piston pin assembly
or the connecting rod, or both.
Standard value:
7,350 - 17,200 N
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9.Check that the piston
moves smoothly.
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1.Fit the oil ring spacer
into the piston ring groove.
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2.
| caution |
Do not use a piston ring
expander when installing side rail.
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Install the upper side rail.
To install the side
rail, first fit one end of the rail into the piston groove,
then press
the remaining portion into position by hand. See
illustration.
| note |
The side rails and spacer may
be installed in either direction.
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| note |
New spacers and side rails are
colored for identification of their
sizes.
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Size
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Identification
color
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Standard
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None
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0.50 mm oversize
diameter
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Red
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3.Install the lower side rail in the same
manner as described in step 2.
4.Make sure that
the side rails move smoothly in both directions.
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1.Using the piston ring
expander, fit number 2 into the number 2 groove of
piston.
| note |
Install piston rings with
identification mark facing up, to the piston
crown side.
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2.Install the number 1 piston ring in the
same manner as step 1.
Identification
mark:
Number 1 ring: 1R
Number 2 ring:
2R
| note |
Confirm the profile for No.1
and No.2 piston rings carefully. Install them
correctly by
careful attention to the direction of top and
bottom.
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| note |
The identification mark and
the size mark are stamped on the upper plane of
the piston
ring (piston top side).
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Size
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Size
mark
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Standard
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None
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0.50 mm oversize
diameter
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50
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3.To prevent wrong installation, check the
identification mark of each piston ring.
The identification mark is stamped near the ring
gap.
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1.Measure the crankshaft pin
diameter and confirm its classification from the following
table. On a crankshaft supplied as a service part,
identification marks of its pins are stamped
at the positions shown in the illustration.
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Crankshaft pin
outside diameter
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Connecting rod
bearing
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Identification
mark
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Size mm
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Identification
mark
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I
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44.995 -
45.000
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1
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II
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44.985 -
44.995
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2
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III
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44.980 -
44.985
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3
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2.If the crankshaft pin outside diameter
identification mark is "I,"
for example, select a bearing whose identification mark is
"1."
If there is no identification color paint on the
crankshaft, measure the pin outside diameter
and select a bearing appropriate for the measured
value.
3.Install the selected bearing in the big
end and in the cap of the connecting rod.
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1.Apply engine oil on the
circumference of the piston, piston rings, and oil
ring.
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.
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4.Not to damage the crank
pin, attach a special tool Bolt guide (MB992010), to the
connecting
rod bolt.
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5.Use suitable thread
protectors on the connecting rod bolts before inserting the
piston
and connecting rod assembly into the cylinder block.
Care must be taken not to nick the crank
pin.
6.Insert the piston and connecting rod
assembly into the cylinder with the front mark
on the piston crown pointing to the timing belt
side.
7.Using a suitable piston ring compressor
tool, install the piston and connecting rod
assembly into the cylinder block.
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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.
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2.Make sure that the
connecting rod big end side clearance meets the
specification.
Standard value: 0.10 -
0.25 mm
Limit: 0.4 mm
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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.
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2.Before installing each
nut, apply engine oil to the threaded portion and bearing
surface
of the nut.
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3.Loosely tighten each nut
to the bolt.
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4.Then tighten the nuts
alternately to the specified torque to install the cap
properly.
Tightening torque: 20 ± 2
N·m
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5.Make a paint mark on the
head of each nut.
6.Make a paint mark on the bolt
end at the position 90 to 94 degrees from the paint
mark made on the nut in the direction of tightening the
nut.
| caution |
- If the nut is turned less
than 90 degrees, proper fastening
performance may not be achieved. Be
careful to tighten the
nut exactly 90 degrees.
- If the nut is overtightened (exceeding
94 degrees), loosen the nut completely
and
then retighten it by repeating the
tightening procedure from step
3.
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7.Turn the nut 90 to 94 degrees and make sure
that the paint marks on the nut and bolt
are aligned.
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