REMOVAL AND INSTALLATION

Removal steps 1. Connecting rod cap nut <<A>> >>G<< 2. Connecting rod cap 3. Connecting rod bearing >>F<< 4. Piston and connecting rod assembly >>E<< 5. Connecting rod bearing >>D<< 6. Piston ring No.1 >>D<< 7. Piston ring No.2 >>C<< 8. Oil ring 9. Snap ring 10. Piston pin >>B<< 11. Piston >>B<< 12. Connecting rod >>B<< 13. Bolt <<B>> >>A<< 14. Connecting rod bush

Mark the cylinder number on the side of the connecting rod big end for correct reassembly.

Use the special tool to remove the connecting rod bush. Component parts of special tool Connecting Rod Bush Puller Kit (MH062574). 1.Secure the connecting rod to the base with the bracket and plate. 2.Attach the collar onto the puller as shown, under a press ram load of approximately 49,035 N.

Use the special tool Connecting rod bush puller Kit (MH062574) to install the connecting rod bush. 1.Apply a thin coat of engine oil to the outside surface of the connecting rod bush and the bush fitting hole in the connecting rod. 2.Set the collar, connecting rod bush and collar on the puller as shown and secure them with the nut. 3.Aligning the oil hole, press-fit the connecting rod bush into the connecting rod slowly under a press ram load of approximately 49,035 N. 4.After press-fitting, ream the connecting rod bush for the specified bush-to-piston pin clearance. Standard value: 0.03 - 0.05 mm caution After reaming, insert the piston pin into the connecting rod bush to ensure that it smoothly moves with little play.

1.When replacing the piston pin, read off the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the following table. Cylinder bore size Piston class Piston size mark A A A B B B C C C note The piston size mark shows on the top of the piston.

2.Mate the piston with the connecting rod. 3.Line up the front marks and insert the piston pin. The piston pin must be smoothly pressed by hand into position. Replace the piston pin if there is an excessive play.

Install the expander coil and oil ring in the piston ring groove.

Use a piston ring expander to install the No.1 and No.2 piston rings. note Size marks on piston rings are as follows. Size Size mark S.T.D None 0.50 mm 50

1.Measure the big end I.D. of the connecting rod (with connecting rod bearing removed) and the pin O.D. of the crankshaft assembly. caution Before measuring the big end O.D. of the connecting rod, tighten the nut to a specified torque. 2.Select connecting rod bearing shells having the thickness that matches the respective measured values from the table below. Install the selected connecting rod bearing shells with their lug fitted in the mating groove of the connecting rod. caution The upper connecting rod bearing shell has an oil hole, while the lower connecting rod bearing shell has no oil hole. Be careful not to install them in wrong place. Crankshaft pin O.D. Connecting rod big end I.D. Compatible connecting rod bearing identification color (Figures in brackets are sheet thicknesses) 53.980 - 53.988 mm 58.010 - 58.019 mm None (1.992 - 1.996 mm) 58.000 - 58.010 mm Blue (1.988 - 1.992 mm) 53.971 - 53.980 mm 58.010 - 58.019 mm Yellow (1.996 - 2.000 mm) 58.000 - 58.010 mm None (1.992 - 1.996 mm)

<Selection by identification color> Select appropriate connecting rod bearings through the combination of the big end I.D. identification color marked on each connecting rod and the appropriate pin O.D. identification color on the crankshaft assembly as shown in the table below. Identification color on crankshaft (Shown in brackets is identification mark) Identification color on connecting rod Compatible connecting rod bearing identification color None (1) None Blue Blue None Blue (2) None None Blue Yellow The crankshaft assembly has additional pin O.D. identification marks ("1" or "2") stamped at as shown. The 4 marks apply to No.1 pin, No.2 pin and so forth sequentially from the engine front to rear.

1.Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. 2.Arrange the piston ring and oil ring gaps (expander coil and spacer) as shown in the figure. 3.Rotate crankshaft so that crank pin is on center of cylinder bore.

4.Use suitable thread protectors on connecting rod bolts before inserting piston and connecting rod assembly into cylinder block. Care must be taken not to nick crank pin. 5.Using a suitable piston ring compressor tool, install piston and connecting rod assembly into cylinder block. caution Insert with the front mark on the piston head directed toward the engine front (timing belt side).

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 come on the same side as shown.

2.Make sure that connecting rod big end side clearance meets the specification. Standard value: 0.10 - 0.25 mm Limit: 0.40 mm 3.The connecting rod cap bolts and nuts are tightened using the torque-to-yield method. For this reason, each bolt to be reused must be checked for elongation before installation. Whether or not the bolt has been elongated can be determined by running a nut with fingers through all the threads of the bolt. If the nut does not turn smoothly over all the threads, the bolt has been elongated and must be replaced. 4.Apply engine oil to the threads and bearing surface of each nut before installation. 5.Finger-tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap properly. 6.Tighten the nuts to a torque of 50 N·m.

7.Make a paint mark on the head of each nut. 8. caution If the tightening angle is less than 90°, adequate tightness could not be assured. If the tightening angle exceeds 90°, loosen the nut completely and then perform the tightening procedure again beginning with the first step. Make a paint mark on the bolt at a point 90° away from the paint mark made on the nut in the tightening direction. 9.Turn the nut 90° to bring the mark on the nut into alignment with that on the bolt.