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Mark the cylinder number on the
side of the connecting rod big end for correct
reassembly.
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1.Not to damage the crank
pin, attach 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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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.
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Cylinder bore
size
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Piston size
mark
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A
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A
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B
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None
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C
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C
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| note |
The piston size mark shows on
the top of the piston.
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2.Set the snap ring into one side of the
piston pin hole.
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3.With the front mark of the
connecting rod and that of the piston located on the same
side, insert the piston pin.
| note |
It is difficult to fit the
piston pin into the piston when they have a
different temperature, Therefore, fit the piston
pin into the piston when they have the same
temperature.
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4.Install the shear drop
side of the snap ring to the piston pin.
5.Check
that the piston moves smoothly.
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Install the expander coil and oil
ring in the piston ring groove.
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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.
Identification marks
No.
1 ring: 1R
No. 2 ring: 2R
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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
(side rail and spacer) as shown in the
figure.
3.Rotate crankshaft so that crank pin is
on centre of cylinder bore.
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4.Not to damage the crank
pin, attach special tool bolt guide (MB992010), to the
connecting rod bolt.
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5.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.
6.
| caution |
Insert with the front mark on
the piston head directed toward the engine front
(timing belt side).
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Using a suitable piston ring compressor tool,
install piston and connecting rod assembly into 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 come on the
same side as shown.
2.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.
3.Apply engine oil
to the threads and bearing surface of each nut before
installation.
4.Finger-tighten the nuts on the
bolts, then tighten the nuts alternately and repeatedly to
install the cap properly.
5.Tighten the nuts to a
torque of 27 ± 2 N·m.
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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.
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Using special tool angle gauge (MB991614), tighten
the connecting rod cap nut in the illustrated sequence by a
further 90° to 94°.
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7.Make sure that connecting
rod big end side clearance meets the
specification.
Standard value: 0.10 -
0.25 mm
Limit: 0.40 mm
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