![](../../../img/11/AK304890AC00ENG.png)
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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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![](../../../img/11/AK305415AB00ENG.png)
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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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![](../../../img/11/AK305425AF00ENG.png)
![](../../../img/11/AK305425AG00ENG.png)
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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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![](../../../img/11/AK306099AD00ENG.png)
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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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![](../../../img/11/AK305774AC00ENG.png)
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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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![](../../../img/11/AK305424AF00ENG.png)
![](../../../img/11/AK305424AG00ENG.png)
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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: 2,000 -
8,000 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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![](../../../img/11/AK304891AA00ENG.png)
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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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![](../../../img/11/AKA00193AF00ENG.png)
![](../../../img/11/AKA00193AG00ENG.png)
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4.The gaps of the side rails
and spacer should be located as illustrated.
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![](../../../img/11/AK304892AB00ENG.png)
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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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![](../../../img/11/AK402172AE00ENG.png)
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Identification
mark
No. 1 ring: T No. 2 ring:
TT
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1.Apply engine oil
sufficiently onto the piston periphery, the piston rings and
the
oil ring.
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![](../../../img/11/AKA00193AF00ENG.png)
![](../../../img/11/AKA00193AG00ENG.png)
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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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![](../../../img/11/AK304896AA00ENG.png)
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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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![](../../../img/11/AK306100AB00ENG.png)
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Measure the illustrated location.
(A -
B) should be within 0.5 mm.
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![](../../../img/11/AK304890AC00ENG.png)
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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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![](../../../img/11/AK304900AA00ENG.png)
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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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![](../../../img/11/AK401052AB01ENG.png)
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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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![](../../../img/11/AK304894AC00ENG.png)
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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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