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Piston and Connecting Rod Assemble > < Piston and Connecting Rod Disassemble

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Piston, Connecting Rod, and Bearing Cleaning and Inspection

Visual Inspection And Cleaning Procedure

Connecting Rod

Warning:  Refer to Safety Glasses Warning .

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1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rod for the following:
  •  Signs of being twisted, bent, nicked or cracked
  •  Scratches or abrasion on the connecting rod bearing seating surfaces

Piston


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1. Clean the piston with a cleaning solvent. DO NOT wire brush any parts of the piston.
2. Clean the piston ring grooves.
3. Inspect the piston on the following:
  •  Cracked ring lands, skirts or pin bosses
  •  Ring grooves for nicks
  •  Eroded areas on the top of the piston (1)
  •  Scuffed or damaged skirts (2)
  •  Worn piston pin bores (3)
4. If there is any excessive wear, replace the piston.
5. Measure the clearance between piston pin and piston bore. Use the following procedure:

Piston And Connecting Rod Measurement Procedure

Piston Pin To Connecting Rod Bore And Piston Bore Clearance

1. Measure clearance between piston pin and connecting rod bore. Use the following procedure:
  1.1 Measure the piston pin outside diameter.
  1.2 Measure the connecting rod bore diameter.
  1.3 Substract the piston ring diameter from the connecting rod diameter.
  1.4 The clearance should be 0.019 mm-0.030 mm (0.0007 in-0.0012 in) .
2. If there is excessive clearance, replace the piston pin.
3. If there is still excessive clearance, replace the connecting rod.
  3.1 Measure the piston pin outside diameter.
  3.2 Measure the piston bore diameter.
  3.3 Substract the piston pin diameter from the piston bore diameter.
  3.4 The clearance should be 0.004 mm-0.014 mm (0.0002 in-0.0006 in) .
4. If there is excessive clearance, replace the piston pin.
5. If there is still excessive clearance, replace the piston.

Piston Ring Clearance


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1. Install the piston rings to the cylinder as shown (1) and measure the piston ring end gap. Compare the measurements with those provided below:
  •  The upper compression ring end gap should be 0.20 mm-0.30 mm (0.0078 in-0.0118 in) .
  •  The lower compression ring end gap should be 1.00 mm-1.50 mm (0.0394 in-0.0591 in) .
  •  The oil ring end gap should be 0.25 mm-0.50 mm (0.0098 in-0.0197) .
2. If the clearance is greater than the provided specifications, the piston rings must be replaced.

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3. Measure the piston ring side clearance as shown (1). Compare the measurements with those provided below:
  •  The upper compression ring side clearance should be 0.11 mm-0.15 mm (0.0043 in-0.0059 in) .
  •  The lower compression ring side clearance should be 0.05 mm-0.09 mm (0.0020 in-0.0035 in) .
  •  The oil ring side clearance should be 0.03 mm-0.07 mm (0.0012 in-0.0028 in) .
4. If the clearance is greater than the provided specifications, replace the piston rings.
5. If the clearance is still to great, replace the pistons.

Connecting Rod Bearing Clearance (With Micrometer Gauge Internal Measuring Device)

1. Install the connecting bearings and the connecting rod bearing caps.
2. Tighten the connecting rod bearing cap bolts in the following sequence:

Caution: Refer to Fastener Caution .
Note:  The old bolts can be reused for the measuring procedure.
  2.1 Tighten the connecting rod bearing cap bolts to 20 N·m (15 lb ft) .
  2.2 Tighten the bolts to an additional 40° .

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3. Measure the connecting rod bearing diameters at 3 points as shown (1). Use a internal measuring device.
4. Calculate the average connecting rod inner diameter.
  Formula: 1. result + 2. result + 3. result / 3

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5. Measure the connecting rod journal diameter at 2 points between (1) and (3) and between (2) and (4). Use a micrometer gauge.
6. Calculate the average connecting rod journal diameter.
  Formula: 1. result + 2. result / 2.
7. Subtract the average connecting rod journal diameter from the average connecting rod bearing diameter in order to determine the connecting rod bearing clearance.
  The clearance should be 0.030 mm-0.062 mm (0.0012 in-0.0024 in) .

Piston and Connecting Rod Assemble > < Piston and Connecting Rod Disassemble