Removal and Installation
REMOVAL AND INSTALLATION
Required Special Tools:
- MD998780: Piston Pin Setting Tool
- MB991659: Guide D
REMOVAL SERVICE POINTS
[[A]] CONNECTING ROD CAP REMOVAL
1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
[[B]] PISTON PIN REMOVAL
1. The special tool MD998780 consists of the elements shown in the illustration.
2. When removing the piston pin, the special tool MB991659 is also used.
3. Insert Push rod, into the piston from the front mark side, then attach Guide D, to the push rod.
4. Place the piston and connecting rod assembly on Base, with the front mark facing up.
5. Use a press to remove the piston pin.
NOTE:
Keep the disassembled pistons, piston pins and connecting rods per cylinder.
INSTALLATION SERVICE POINTS
]]A[[ PISTON PIN INSTALLATION
1. When replacing the piston, note the cylinder bore size mark on the cylinder block as illustrated, and select a piston according to the flowing table.
NOTE:
The piston size mark shows on the top of the piston.
2. Insert the push rod into the piston pin and install the guide A.
3. Align the front mark of the piston with that of the connecting rod. Align the piston with the connecting rod.
4. Apply engine oil to the outer circumference of the piston pin.
5. Insert the piston pin guide A installed at step 2 into the pin hole from the front mark of the piston.
6. Screw the guide B into A until the clearance "L" reaches 3.75 mm (0.147 inch) between A and B.
7. Place the piston and connecting rod assembly onto Base, with the front marks facing up.
8. Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston pin assembly or the connecting rod, or both.
Standard value: 5,000 - 15,000 N (1,124 - 3,372 lb)
9. Check that the piston moves smoothly.
]]B[[ OIL RING INSTALLATION
1. Fit the oil ring spacer into the piston ring groove.
NOTE:
The side rails and spacer may be installed in either direction.
CAUTION:
Do not use any piston ring expander when installing the side rail. If will break the side rail.
2. Install the upper side rail.
To install the side rail, first fit one end of the rail into the piston groove, then press the remaining portion into the position by finger. See illustration.
3. Install the lower side rail in the same procedure as described in step 2.
4. Make sure that the side rails move smoothly in both directions.
]]C[[ PISTON RING NUMBER2 / PISTON RING NUMBER1 INSTALLATION
To prevent wrong installation, check the identification mark of each piston ring. The identification mark is stamped near the ring gap:
Identification mark
Number 1 ring: 1T
Number 2 ring: 2T
]]D[[ CONNECTING ROD BEARING INSTALLATION
1. If the connecting rod bearing is replaced, select based on the identification mark of crankshaft (illustrated) and the table shown below.
2. Every connecting rod bearing is identified by the identification color at the illustrated location.
3. Install the selected bearing in the big end and in the cap of the connecting rod.
]]E[[ PISTON AND CONNECTING ROD INSTALLATION
1. Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
2. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on the center of the cylinder bore.
4. Insert the piston and connecting rod assembly into the cylinder with the front mark on the piston crown pointing to the timing belt side.
5. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly into the cylinder block.
]]F[[ CONNECTING ROD CAP INSTALLATION
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 are on the same side as shown.
2. Make sure that the connecting rod big end side clearance meets the specification.
Standard value: 0.10 - 0.25 mm (0.004 - 0.009 inch)
Limit: 0.4 mm (0.02 inch)
]]G[[ CONNECTING ROD BOLT INSTALLATION
1. Apply engine oil to the threaded portion and seating face of the bolt.
2. To correctly install the cap, loosely install the bolts with fingers.
3. Alternately, tighten the bolts in several steps to the specified torque of 20 ± 2 Nm (15 ± 1 ft-lb).
4. Make a paint mark on the head of each bolt.
5.
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.
Put another paint mark on the bolt head at 90 degrees in the tightening direction from the first paint mark.
6. Tighten the bolt 90 degrees. The paint mark on the connecting rod should be aligned with the paint mark on the bolt.