Connecting Rod: Testing and Inspection

INSPECTION
1. Inspect connecting rods.

A. Inspect Connecting Rod Alignment.





Using a rod aligner and a feeler gauge, check the connecting rod alignment.
- Check for out-of-alignment.
Maximum out-of-alignment: 0.05 mm (0.0020 inch) per 100 mm (3.94 inch)
If out-of-alignment is greater than maximum, replace the connecting rod assembly.





- Check for twist.
Maximum twist: 0.15 mm (0.0059 inch) per 100 mm (3.94 inch)
If twist is greater than maximum, replace the connecting rod assembly.

B. Inspect Piston Pin Oil Clearance.





(a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing.
Bushing inside diameter: 24.008 - 24.017 mm (0.9452 - 0.9455 inch)





(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 24.000 - 24.009 mm (0.9449 - 0.9452 inch)
(c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.05 - 0.011 mm (0.0002 - 0.0004 inch)
Maximum oil clearance: 0.015 mm (0.0006 inch)
If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.

C. If Necessary, Replace Connecting Rod Bushing.





(a) Using Special Service Tool (SST) Connecting Rod Bushing Remover & Replacer # 09222-40011 or equivalent and a press, press out the bushing.





(b) Align the oil holes of a new bushing and the connecting rod.





(c) Using SST and a press, press in the bushing.





(d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin.





(e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

D. Inspect Connecting Rod Bolts.





(a) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread.





(b) If the cap nut cannot be turned easily, measure the outside diameter of the connecting rod bolt with vernier calipers.
Standard outside diameter: 7.8 - 7.9 mm (0.307 - 0.311 inch)
Minimum outside diameter: 7.5 mm (0.295 inch)

NOTE: If the location of this area cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration.
If the outside diameter is less than minimum, replace the connecting rod bolt and nut as a set.