Service Specifications

Piston and connecting rod





2. Connecting rod bearing cap
^ Do not interchange
^ Mark allocation to cylinder using a color marker - B -
^ When installing bearing cap, observe: The wide thrust flange - A - must point to same side on connecting rod and connecting rod bearing cap
^ Installation position of connecting rod pairs

5. Piston pin
^ If tight, heat piston to 60°C

8. Piston rings
^ Offset gaps by 120°





Checking piston ring gap
- Push ring squarely from above down to approximately 15 mm from bottom end of cylinder. To do this use a piston without rings.








Checking ring to groove clearance

- Clean ring groove of piston before checking.







Checking piston
- Measure approximately 10 mm from lower edge, at a 90° angle to piston pin axis using an external micrometer 75 to 100 mm.
^ Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension Piston and cylinder dimensions.





Checking cylinder bores
- Using an internal dial gauge 50 to 100 mm, measure at 3 points in diagonal sequence horizontally - A - and vertically - B -.
^ Maximum deviation from nominal dimension: 0.08 mm.
Nominal dimension Piston and cylinder dimensions.





Installed position of piston and piston/cylinder allocation
- Mark installed location and allocation to cylinder on piston head using chalk or water-proof felt pen.

Note: Do not use a center punch or scribe, since the piston head coating will be damaged.

^ Installed location: Arrow on piston face points toward belt pulley side.





Mark connecting rod

Note:
^ Only replace connecting rod as a set.
^ Do not interchange connecting rod bearings.

- Before removing, mark allocation of connecting rod and connecting rod bearing caps to each other and to cylinder with paint - arrow -.





Connecting rod





1. Connecting rod bolt 30 Nm plus an additional 90° (1/4 turn)


Main Bearing Cap





Replace bolts - 1 to 16 -.
Place long bolts into inner row of bearing bracket.
Tighten bolts for bearing bracket as follows:
Tighten bolts - 1 to 16 - using torque wrench 50 Nm.
Tighten bolts - 1 to 16 - 90° (1/4 additional turn) using a rigid wrench.
Tighten bolts for sealing surfaces of cylinder block/bearing bracket - dark hatching - in illustration 23 Nm in diagonal sequence.


Crankshaft Pulley