| 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 MH062574 - Connecting Rod Bush Puller Kit
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 push-to-piston
pin clearance.
Standard value: 0.03 - 0.05 mm
Limit: 0.1 mm
| caution | After reaming, insert the piston pin 10 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. The ring identification
mark should face upwards.
| note | Size marks on piston rings are as follows.
|
| Size
| Size mark
| S.T.D
| None
| 0.50 mm
| 50
|
|
|
| The connecting rod bearing to be used must have an appropriate thickness that matches
the big end I.D. of the connecting rod and the pin O.D. of the crankshaft assembly. There are
two methods available for selecting an appropriate bearing.
|
| <Selection by measurement>
|
| 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.
2.
| caution | Before measuring the big end O.D. of the connecting rod, tighten the nut
to a specified torque.
|
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 (arrow) 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 29 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.
|
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