Piston: Service and Repair

REMOVAL





NOTE: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly.

1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top of the cylinder.

INSTALLATION





1. Install the spacer.





2. Install upper side rail. To install side rail, first put one end of side rail between piston ring groove and spacer, hold it down firmly, then press down with your finger the portion to be inserted into groove as illustrated.

NOTE: Do not use piston ring expander when installing side rail.





3. Install lower side rail by same procedure as Step 2.
4. Using piston ring expander, install No.2 piston ring.
5. Install No. 1 piston ring.
6. Apply engine oil around piston and piston rings.





7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that gaps are not positioned in side rail thrust and pin directions.
8. Hold piston rings firmly in a piston ring compressor as you insert them into cylinder.





9. Make sure that front mark of piston and front mark (identification mark) of connecting rod are directed toward front of engine.
10. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match.
11. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
12. Tighten the connecting rod cap nuts.
Tightening torque:
Connecting rod cap nuts: 50-53 Nm (50-53 kg.cm, 36-39 ft. lbs.)





13. Check connecting rod side clearance.
Standard value: 0.10-0.25 mm (0.004-0.0098 inch)
Limit: 0.4 mm (0.0157 inch)