Connecting Rod

DISASSEMBLY

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, then remove the caps and the big end lower bearing.
2. Push each piston connecting rod assembly toward the top of the cylinder.

INSPECTION
CONNECTING RODS





1. When reinstalling, make sure that cylinder numbers put on the connecting rod and 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 if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod: 0.05 mm/100 mm (0.0020 inch/3.94 inch) or less
Allowable twist of connecting rod: 0.1 mm/100 mm (0.0039 inch/3.94 inch) or less

REASSEMBLY





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 the portion to be insert with your finger 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 the front mark of piston and the 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: 35-38 Nm (350-380 kg.cm, 25-28 ft. lbs.)





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