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Using the special tool Piston ring
tool (MH060014), remove each compression ring.
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1.Remove the piston pin
using an appropriate push - out bar.
2.If the
piston pin is hard to remove, warm the piston over a heater
or in hot water
before removal.
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1.Measure the piston
pin-to-bush clearance. If the clearance exceeds the
specified service
limit, replace defective part.
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2.Use the special tool
Connecting rod bush puller kit (MH062455) to replace the
connecting
rod bush. Component Parts of Special Tool Connecting rod
bush puller kit (MH062455).
A:
Collar
B: Collar
C: Puller
D: Base
E:
Bracket
F: Plate
G:
Nut
3.Remove the upper connecting
bearing beforehand, if attached, from the big end of the
connecting rod.
4.Secure the connecting rod to the
base D with the bracket E and plate F.
5.Attach
the collar A onto the puller C as shown, and remove the
connecting rod bush
slowly under a press ram load of approximately 50,000
N.
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1.Apply a thin coat of
engine oil to the peripheral surface of the connecting rod
bush and
the bush mounting hole in the connecting
rod.
2.Set the collar B, connecting rod bush and
collar A and the puller C in the connecting
rod as shown and secure them with the nut
G.
3.Bring the oil holes in alignment at H and
press-fit the connecting rod bush into the
connecting rod slowly under a press ram load of
approximately 50,000 N.
4.After press-fitted, ream
the connecting rod bush up to the specified bush-to-piston
pin clearance.
| caution |
After reaming, insert the
piston pin in the bush and check to
see that it smoothly moves without
play.
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1.Select pistons that bear
the same size marks (A, B or C) as the cylinder size marks
stamped
on the crankcase.
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2.Apply a thin coat of
engine oil to the piston pin prior to installation. Assemble
the
connecting rod and the piston with the mark "o" and the
front mark facing in the directions shown,
and insert the piston pin.
3.If the piston pin is
hard to insert, warm the piston by a piston heater or in hot
water.
| caution |
Check that the piston moves
smoothly without excessive play.
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1.Install the oil ring with
its end gaps positioned at A and the butting end of the
expander
spring positioned at B shown in the
illustration.
2.Install the compression rings with
their manufacturer’s marks C near the
end gaps facing upward.
3.Set the end gaps of the
compression rings to the positions shown in the
illustration.
D: End gap of the 1st compression
ring
E: End gap of the 2nd compression ring
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1.
| caution |
- Be sure that the end gap
of all the piston rings is in position.
Location of piston ring end
gap.
- Be careful not to damage the piston head
(combustion chamber).
- Be careful not to hit the connecting rod
against the oil jet.
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2.Install the piston with
the from mark facing towards the engine front.
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3.Use a Piston guide
(MH062226) to hold the piston rings compressed when
inserting the piston
and connecting rod assembly into the cylinder.
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4.Insert the piston and
connecting rod assembly. Apply a thin coat of engine oil to
the
threaded part of the connecting rod bolt.Install the
connecting rod cap with the lugs of the
upper and lower connecting rod bearing at the same
side.
5.Tighten the nuts alternately in the
following manner.
- Tighten the nuts to 30 N·m first.
- Then, torque them further to 50 N·m.
- Give them a 45°
±
5°
clockwise turn to tighten additionally.
- Finally, give them another 45°
±
5°
turn.
| caution |
After all the
connecting rod caps are installed, check
the
following:
Connecting
rod end play.
Piston
protrusion.
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The connecting rod bearings must
have a proper plate thickness that matches the difference
between the big end I.D. of the connecting rod and the pin
O.D. of the crankshaft.
- Measure the big end I.D. of the connecting
rod (with bearings
removed) and the pin O.D. of the
crankshaft.
Connecting rod: One
point in vertical direction
Crankshaft: One point
in any direction
-
| caution |
- Tighten the nuts by
specified procedure
before measuring the
connecting rod big end
I.D.
- For the service parts, the
above dimensions can be
identified by the
identification
colors on the connecting rod
and
crankshaft.
The
pin O.D. of the crankshaft
is also indicated by
the identification marks "1"
or "2" stamped at the
position shown in the
illustration.
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- Select appropriate thicknesses of the
connecting rod bearing from the following
table and install them while locating the lugs in
position.
The connecting rod bearings also have
the identification colors.
| caution |
When installing the
bearings, be sure to set the upper
bearing
without oil hole in their correct
positions.
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Crankshaft
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Connecting
rod
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Connecting rod
bearing
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Identification color
(Identification mark)
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Pin O.D. (mm)
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Identification color
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Big end I.D.
(mm)
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Identification
color
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Plate thickness
(mm)
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Oil clearance
(mm)
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None (1)
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54 -0.012
-0.0200
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Blue
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58 +0.019
+0.010
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None
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2 -0.004
-0.008
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0.030 -
0.055
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None
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58 +0.010
0
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Blue
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2 -0.008
-0.012
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0.028 -
0.054
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None (2)
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54 -0.020
-0.029
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Blue
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58 +0.019
+0.010
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Yellow
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2 0
-0.004
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0.030 -
0.056
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None
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58 +0.010
0
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None
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2 -0.004
-0.008
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0.028 -
0.055
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1.Check that the bolt hole A
in the connecting rod is free of damage, burrs,
etc.
2.Apply a thin coat of engine oil to the
connecting bolt at the point B, and install
it in the connecting rod with the notch C in the head
inward.
C: Nick in bolt head
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