Pistons and Connecting Rod
REMOVAL
Connecting rod cap
Caution: 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.
Piston pin removal and installation procedures
1. Use the special tools (09234-33001) disassemble and reassemble the piston and connecting rod.
2. Place the proper insert using a tool between the connecting rod and the piston.
3. Insert the proper removing tool through the hole.
Caution: After removing the piston rod pin assembly, put it in the center of the arbor.
4. Press the piston pin out of the connecting rod.
5. Install proper pin guide (refer to application chart) through piston into connecting rod. Hand tap pin guide into piston for proper retention. Drop piston pin into the other side of the piston.
Caution: The pin guide centers on the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center on this assembly in the tool. If a pin guide that is too small is used, the piston assembly will not be located at center of the tool, and it may cause the fork and/or the insert of the tool to be damaged.
6. Install piston assembly onto fork assembly of tool. Tool will support connecting rod at the piston pin. Be sure piston assembly is slid onto the fork until the pin guide contacts the fork insert.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alphanumeric setting from the application chart is obtained.
8. Insert the installing arbor through the hole in the arch of the tool. Press the piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed in.
Caution: Do not exceed 5000 pounds of force when stopping the installing the arbor sleeve against the arch.
INSPECTION
Piston and piston pin
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When replacing the piston, its rings should also be replaced.
3. Check the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective.
Piston ring
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in a ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings together. if it is less than the service limit, replace the piston rings only.
Piston ring side clearance
Standard value
3.5 L
No.1: 0.04 - 0.08 mm (0.0016 - 0.0315 inch)
No.2: 0.02 - 0.06 mm (0.0008 - 0.0024 inch)
Limit
No.1: 0.1 mm (0.0039 inch)
No.2: 0.1 mm (0.0039 inch)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring.
Piston ring end gap
Standard dimensions
3.5 L
No.1: 0.20 - 0.30 mm (0.0079 - 0.0118 inch)
No.2: 0.45 - 0.60 mm (0.0177 - 0.0236 inch)
Oil ring: 0.20 - 0.70 mm (0.0079 - 0.0276 inch)
Limit
No.11, No.2: 0.8 mm (0.031 inch)
Oil ring side rail: 1.0 mm (0.039 inch)
When replacing the ring without correcting the cylinder bore, check the gap with the ring positioned at the lower part of cylinder that is less worn. When replacing a ring, be sure to use a ring of the same size.
Piston ring limit and mark
Standard: No mark
0.25 mm OS: 25
0.50 mm OS: 50
0.75 mm OS: 75
1.00 mm OS: 100
Notice: The mark can be found on the upper side of the ring next to the end.
Connecting rod
1. When the connecting rod cap is installed, make sure that cylinder numbers put on the rod end cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod it it is damaged on the thrust faces at either end, and also if it has a step wear in, or severely rough surface of the inside diameter of the small end.
INSTALLATION
1. Install the spacer.
2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it down firmly, and then press down the portion which is to be inserted into the groove with a finger as illustrated.
Caution: Do not use a piston ring expander when installing side rail.
3. Install the lower side rail by the same procedure as Step 2.
4. Apply engine oil around the piston and piston rings.
5. Using a piston ring expander, install the No.2 piston ring.
6. Install the No.1 piston ring.
7. Position each piston ring end gap as far apart from neighboring gaps as possible. Make sure that the gaps are not positioned in the direction vertical to the pin.
8. Hold piston rings firmly by a piston ring compressor as they are inserted into cylinder.
9. Install the upper main bearings in the cylinder block.
10. Install the lower main bearings in the main bearing caps.
Caution: Install the bearing with the oil hole in the b1cok.
11. Install the thrust washers in No.3 main bearing cap with the oil grooves facing outward.
12. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure that the cylinder numbers put on the rod and cap at disassembly match.
14. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
15. Connecting rod bolts should be fastened. (Bolt & nut should be not reused.)
Tightening torque
Connecting rod bolt: 33 - 37 Nm (330 - 370 kg-cm, 24.34 - 27.29 ft. lbs.) + 90° - 94°
16. Check the bearing clearance as follows:
1) Remove oil and dirt from the bearings and journals.
2) Cut Plastigage to the same length as the width of the bearing and place it in parallel with the journal, avoiding the oil holes.
3) Install the bearing and cap. Tighten to the specified torque. During this operation, do NOT turn the crankshaft.
4) Remove the cap, measure at the widest part by using the scale printed on the Plastigage package.
Connecting rod cap bearing clearance
Standard value: 0.022 - 0.040 mm (0.0009 - 0.0016 inch)
Limit: 0.1 mm (0.0039 inch)
17. Check the connecting rod side clearance.
Connecting rod side clearance
Standard value: 0.10 - 0.25 mm (0.0039 - 0.00984 inch)
Limit: 0.4 mm (0.016 inch)