ENGINE OVERHAUL 11B-87 PISTON AND CONNECTING ROD, PISTON AND CONNECTING ROD REMOVAL AND INSTALLATION ‘Removal sept Connecting rod cap mt Connecting fod cap (Conneting rod bering <4. Pst and connecting rod assembly 5 Connecting rod bearing “C6. Past ag No.1 so CocT Bites sag No.211B-58 ENGINE OVERHAUL PISTON AND CONNECTING ROD. REMOVAL SERVICE POINTS -<> CONNECTING ROD CAP REMOVAL, [Mark the cylinder number on the side ofthe conneet- ‘ng rod big end forcomect reassembly. PISTON AND CONNECTING ROD. ASSEMBLY REMOVAL, 1. Not to damage the crank pin attach a special tool Bolt guide (MB992010), tothe connecting rod ote 2. Remove the piston and conaccting rod assembly ‘from the cylinder block: INSTALLATION SERVICE POINTS >> Acc CONNECTING ROD / SNAP RING / PISTON Cylinder bore size Piston ize mark ny x @ Nene c © NOTE: The psion size mark shows on the top of the piston 2. Sertho snap sing into one sid ofthe piston pin hole Except Euro 5> Frnt mak e Front mack us Frontmark 4. With the fione mask of the connecting rod and that cof the piston located on the same side, insert the piston pin. NOTE: Iti difficult to fit the piston pin into the ps- {on when they havea different temperature, Therefore fit the piston pin into th piston when ‘hay have the same temperature 4. Set the snap sing into the other side ofthe piston pin hole 5. Check that the piston moves smoothly. PIN/ PISTON INSTALLATION >>Be< OIL RING INSTALLATION Ting bat se Expand ei i Not Ne? NBS No oiljng ot oeee: J" > 1, When replacing the piston pio, read off the ‘ulinder bore size mark onthe cylinder block as sllusuated, ond select a piston according (0 the following table Install the expander coil end oil ring i the piston sing rove.ENGINE OVERHAUL 118-59 PISTON AND CONNECTING ROD. >=Cx< PISTON RING Ne INSTALLATION 1 PISTON RING NO. 2 dentfeaton rar Sizemarts >>De< PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION 1 Liberally coat engine oi on the circumference of the piston, piston ring, and ol ring 2. Arrange the piston ring and oil ing gaps (side ail and spacet) as shown in the figure 43. Rotate crankshaft so that crank pin ison center of cvlinder bore 4. Not to damage the crank pin, attach a special to! Bolt guide (MB997010), tothe connecting rod bolt 5. Use suitable thread protectors on consecting rod Dolis before inserting piston and connecting rod assembly into cylinder block. Care must be taken ott nick exank pin. 6. Using a suitable piston ring compressor tool, instal piston and connecting rod assembly into cylinder Block ‘CAUTION, Tsert with the front mark om the piston head directed toward the engine front (timing belt side, >>E<< CONNECTING ROD CAP/ CONNECTING ROD CAPNUT INSTALLATION11B-60 ENGINE OVERHAUL PISTON AND CONNECTING ROD 1. Verfing the mark made dusing disassembly ‘stall the easing cap tothe connecting sod Ifthe ‘comecting rod is new with no index mask, make sore that the bearing locking notches come on the same sde as shown. 2. The connecting rod exp bots and mus are tightened using the torque-to-yield method, For this reason, each bolt to he sensed mast be ‘checked for elongation before instalation, ‘Whether or not the bolt has been elongated ca, bbe determined by manning ant with fingers ‘tough al the threads ofthe bol. I the nut does ‘not tum smoothly overall the thread, the bolt has ‘been elongated and ssust be replaced 1. Apply engine oil to the treads and beating sufice of cach nit before installation 4. Finger tighten the nuts on the bolts, then tighten the nuts alternately and repeatedly to install the cap property 5. Tighten the aut to a torque of 27 42N-m. 6. Using the special tool Angle gage (MB991614), ‘tighten the connecting rod cap nut in the illustrated sequence by a further 90 P10 94°. (A, caution _] "When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity eannot 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. 7. Male sure that connecting sod big end side clearance meets the specification Standard value:0.10 ~ 0.2mm Limit: 0.40 mm INSPECTION PISTON RING Piston Tics "No otsing groove a 2) ing ear lI 1. Check fr side clearance. Ifthe limit is exceeded, replace the ring or piston, or both NOTE: In cases of keystone pe, measure the ing © groove clearance as sav, Standard valve: No1:007 ~0.10mm No.2:0.05 —0.06 mm it: 0.02 ~ 0.06 min Limit No.1: 018mm No.2: it: 0.10 mm Y Y Freeing down snp et eeENGINE OVERHAUL 11B-61 PISTON AND CONNECTING ROD 2. Insert the piston ring into cylinder bore. Force it >E== PIIB-SS (CRANKSHAFT PIN OH. CLEARANCE, (PLASTIGAGE METHOD) 1. Wipe off ol fom the crankshaft pin and connecting sod bearing ea Standard value [Limit] 4 Remove the nuts, then remove the connecting rod ma mm cap carefully Not [Except ured 03) =F oF Bares 020 = 030 oF Nod | Except Eured 030 = 04S oF Eras 020 = 035 oF OF 025 = OF oF ‘5. Measure the largest width of the crushed plastigage using the ruler printed on the bag of the plastignge ‘Standard valuo: 0.02 Limit: 0.1 mama ~ 0.05 ms