Pistons And Connecting Rod Overview

1. Bolts
   • 30 Nm + 90°
   • Replace
   • Lubricate the thread and contact surface.
2. Connecting Rod Bearing Cap
   • Mark for installation later.
   • Mark allocation to the cylinder with paint -B-, refer to Fig 8.
   • Installation position: casting markings -A-.
3. Bearing Shells
   • Pay attention to the installed position.
   • Mark used bearing shells for reinstallation but not on the running surface.
   • Replace the bearing shells worn down to the base layer.
4. Connecting Rod
   • Always replace as a set.
   • Mark allocation to the cylinder with paint -B-, refer to Fig 8.
   • Installation position: note the casting markings -A- and, refer to Fig 9.
   • Axial play for each new connecting rod pair: 0.20 to 0.44 mm
   • Radial Play, Measuring. Refer to CONNECTING ROD, MEASURING RADIAL CLEARANCE .
5. Locking Ring
   • Replace
6. Piston Pin
   • Heat piston to 60° C if it is difficult to move.
   • Remove and install with the Pilot DriftVW222A.
7. Piston
   • Mark the installation position and cylinder allocation Fig 7.
   • Replace the piston if there are cracks on the piston head or piston shaft.
   • Checking. Refer to Fig 5.
   • Install with piston ring compressor.
   • Piston and Cylinder Dimensions. Refer to PISTON AND CYLINDER DIMENSIONS .
   • Measuring cylinder bore, refer to Fig 6.
   • Measure the piston projection at "TDC". Refer to PISTON PROJECTION, MEASURING AT "TDC" .
8. Piston Rings
   • Offset gaps by 120°
   • Use piston ring pliers for Removing and Installing.
   • Mark "TOP" must face toward piston head.
   • Measuring the gap, refer to Fig 3.
   • Measuring side clearance, refer to Fig 4.

1. Bolt - 9 Nm
2. Oil Spray Jet for Cooling the Piston And Spray Jet Valve

-- Push the piston ring squarely from above down to approximately 15 mm from the bottom end of the cylinder.

-- To do this use a piston without piston rings.

Piston Ring	New mm	Wear Limit mm
1. Compression ring	0.25 to 0.38	0.80
2. Compression ring	0.70 to 0.90	1.30
Oil scraping ring	maximum 0.40	0.70

-- Clean the piston ring groove before checking.

Piston Ring	New mm	Wear Limit mm
1. Compression ring	0.120 to 0.160	0.175
2. Compression ring	0.020 to 0.090	0.115
Oil scraping ring	0.020 to 0.090	0.115

-- Measure approximately 10 mm from the lower edge at a 90° angle to the piston pin axis using a 75 to 100 mm external micrometer.

• Maximum deviation from the specified dimension: 0.05 mm.

Nominal dimension. Refer to PISTON AND CYLINDER DIMENSIONS .

-- Measure in a diagonal sequence at three positions transversely -A- and longitudinally -B- using a Cylinder Dial Bore GaugeVAS6078.

• Maximum deviation from the specified dimension: 0.08 mm.

Nominal dimension. Refer to PISTON AND CYLINDER DIMENSIONS .

• Installation position: arrow -item 1- on the piston head toward the pulley side

-- Mark the connecting rod and connector rod bearing caps to each other and to the cylinder -arrow- with paint for installation.

• Installation position: the larger connecting rod thrust flange -arrows- faces the crankshaft bearing