|
Mark the cylinder number on the
side of the connecting rod big end as a guide for
reassembly.
|
|
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.
|
|
The special tool, Piston pin
setting tool (MD998780), consists of the elements shown in
the drawing.
|
|
1.Insert the tool element,
Push rod, into the piston from the front mark side (notched
side), then attach the tool element, Guide C, to the push
rod.
2.Place the piston and connecting rod
assembly on the tool 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.
|
|
|
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.
|
|
Cylinder bore size
mark
|
Piston size
mark
|
I
|
A
|
II
|
No mark
|
III
|
C
|
|
| note |
The piston size mark is
located on the piston top surface.
|
2.Insert the tool element, Push rod, into the
piston pin and attach the tool element, Guide A (21.9 mm) 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
2.) into the piston pin holes from the front marked side of
the piston.
|
|
6.Screw the guide B into the
guide A until the gap Insert guide B into guide A with
having 3 mm of the clearance "L" between guide A and
B.
|
|
7.Place the piston and
connecting rod assembly onto the tool 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 -
17,100 N
|
|
1.Fit the oil ring spacer
into the piston ring groove.
|
|
| caution |
Use of ring expander to expand
the side rail end gap can break the side rail,
unlike the other piston rings.
|
2.Install the upper side rail, then the lower
side rail.
To install each side rail, first fit one end
of the rail into the piston groove, then press the remaining
portion progressively into position by finger as shown in
the drawing.
3.Make sure that the installed side
rails move smoothly in either direction.
|
|
Using a piston ring expander,
install the piston rings with their identification marks
facing up (toward the piston
head).
Identification marks
No.1
ring: 1R
No.2 ring: 2R
|
|
1.When replacing the
connecting rod bearing, select a bearing of the size
appropriate for the crankshaft pin diameter in accordance
with the crankshaft pin and connecting rod bearing matching
table shown below.
2.Crankshaft pin diameter marks
are stamped in the indicated locations.
|
|
3.Connecting rod bearing
identification mark/colour is stamped/painted in the
indicated location on each bearing.
|
|
Crankshaft
pin
|
Connecting rod
bearing
|
Identification
mark
|
Diameter
mm
|
Identification mark
or colour
|
I
|
44.995 -
45.000
|
1 or Yellow
|
II
|
44.985 -
44.995
|
2 or None
|
III
|
44.980 -
44.985
|
3 or Blue
|
|
4.<Bearing selection
example>
If the crankshaft pin diameter mark is "I"
select a bearing marked "I" or "Yellow."
If the
crankshaft pin diameter mark is illegible, measure the pin
diameter and select a bearing with the mark corresponding to
the measurement.
5.Install the upper and lower
halves of the selected bearing on the connecting rod big end
and cap, respectively.
|
|
|
1.Apply engine oil
generously to the piston’s outside surface, piston
rings, and oil ring.
|
|
2.Align the end gaps of the
piston rings and oil ring (side rail and spacer) as shown in
the drawing.
3.Insert the piston and connecting
rod assembly from the top of cylinder with the front mark
notch on the head toward the camshaft sprocket.
|
|
4.Not to damage the crank
pin, attach a special tool Bolt guide (MB992010), to the
connecting rod bolt.
|
|
5.Use a piston ring band to
hold the piston rings compressed when inserting the piston
and connecting rod assembly into the cylinder. Do not strike
the assembly with a large force. Doing so could break the
piston rings and crank pin.
|
|
1.Install the bearing cap on
the connecting rod while aligning the marks made during
disassembly. If the connecting rod is new and has no
alignment mark, assemble it with the cap such that both
bearing locating notches are on the same side as shown in
the drawing.
|
|
2.Make sure that the thrust
clearance of the connecting rod big end is
proper.
Standard value: 0.10 - 0.25
mm
Limit: 0.4 mm
|
|
|
1.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.
|
|
|
2.Apply engine oil to the
threads and bearing surface of each nut before
installation.
|
|
|
3.Finger-tighten the nuts on
the bolts, then tighten the nuts alternately and repeatedly
to install the cap properly.
|
|
|
4.Tighten the nuts to a
torque of 20 ± 2 N·m.
|
|
5.Make a paint mark on the
head of each nut.
6.
| 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.
|
Make a paint mark on the bolt at a point 90°
to 94° away in the tightening direction from the paint
mark made on the nut.
7.Turn the nut 90° to
94° to bring the mark on the nut into alignment with
that on the bolt.
|
