42 02 PISTON AND CONNECTING ROD 1. No.1 compression ring 2. No.2 compression ring 3. Oil ring Description Cylinder bore diameter Piston outer diameter (D1) Clearance between bore and piston Piston cooling gallery Pin offset Compression ratio Length of piston pin Material of top ring / coating Tightening torque of connecting rod bolt Permissible weight difference of connecting rod Thickness of connecting rod bearing (Red) Thickness of connecting rod bearing (Yellow) Thickness of connecting rod bearing (Blue) ENG φ 86.2 (0~0.018) mm φ 86.133 (±0.009) mm 74 Applied 0.15 mm (Thrust) 17.5 : 1 71.2 mm Steel / Gas nitride 40 ± 5.0 Nm, 90 + 10 4 g 1.806 ~ 1.809 mm 1.809 ~ 1.812 mm 1.812 ~ 1.815 mm
02 43 PISTON RING 1. No.1 compression ring 2. No.2 compression ring 3. Oil ring 5. Coil spring and oil control ring 6. Hook spring Replacement of Piston Ring 1. Measure piston ring end gap. 1) Piston ring end gap (mm) 1st groove: 0.20 ~ 0.35 2nd groove: 0.20 ~ 0.35 3rd groove: 0.20 ~ 0.40 2) Clearance between piston ring and piston (mm) 1st compression ring: 0.075 ~ 0.119 2nd compression ring: 0.050 ~ 0.090 3rd oil ring: 0.030 ~ 0.070 SENSOR CONTROL FUEL COOLING LUB EXHAUST INTAKE HOUSING ASSY GENERAL 3. Install the piston so that Y marking on piston head is facing in the direction of travel. Arrange the piston ring ends to be 120 apart. 4. Adjust the hook spring joint in the oil ring 180 away from the ring end.
44 02 CYLINDER INNER DIAMETER AND PISTON SIZE (Unit : mm) Code Used piston Cylinder Diameter Piston Diameter A A or X 86.200 ~ 86.206 86.124 ~ 86.130 X A, B or X 86.206 ~ 86.212 86.129 ~ 86.137 B B or X 86.212 ~ 86.218 86.136 ~ 86.142 + 5 + 5 86.250 ~ 86.260 86.167 ~ 86.181 + 10 + 10 86.300 ~ 86.310 86.217 ~ 86.231
02 45 DISASSEMBLY AND REASSEMBLY 1. Install the compression ring and oil ring on the piston with a special tool. GENERAL Arrange the piston ring ends to be 120 apart. Install the No.1 and No.2 pistons so that Y marking on piston head is facing upward. No.1 piston ring is thicker than No.2 piston ring. Arrange the oil ring end to opposite position of current ring end. Oil ring is not directional. Make sure that the piston ring end is not aligned to axial direction and lateral direction. 2. Check the clearance of piston oil ring and compression ring with a thickness gauge and adjust if necessary. 1st groove 2nd groove 3rd groove Piston ring end play (mm) 1st groove: 11.0 mm 2nd groove: 10.5 mm 3rd groove: 7.0 mm 0.20 ~ 0.35 mm 0.20 ~ 0.35 mm 0.20 ~ 0.40 mm SENSOR CONTROL FUEL COOLING LUB EXHAUST INTAKE HOUSING ASSY 3. Check the clearance of piston rings with a thickness gauge and adjust if necessary. No.1 compression ring 2nd compression ring 3rd oil ring 0.075 ~ 0.119 mm 0.050 ~ 0.090 mm 0.040 ~ 0.080 mm
46 02 4. Fit the piston onto connecting rod so that the marking on piston crown and locking slot are facing to straight ahead direction. Install the piston so that the piston recess (marking) or the stamped surface of connecting rod is facing to straight ahead direction. 5. Lubricate piston pin and push in by hand. Do not heat up the piston. 6. Place new snap rings into the grooves. The snap rings should be replaced with new one. 7. Lubricate the cylinder bore, connecting rod bearing journals, connecting rod bearing shells and pistons. 8. Push piston into the cylinder with a wooden stick. 9. Insert connecting rod bearing shells. The upper and lower connecting rod bearings have same appearance. Therefore, make sure to check the part number before replacing them. Install bearing rod bearing cap so that the retaining lugs are on the same side of the connecting rod bearing.
02 47 10. Measure stretch shaft diameter of the connecting rod bolts. Limit C 7.1 mm GENERAL 11. Lubricate the new connecting rod bolts and tighten. Installation Notice Tightening torque End play of connecting rod cap Specified value 40 ± 5.0 Nm, 90 + 10 0.5 ~ 1.5 mm 12. Position piston to TDC and measure the distance between piston and mating surface of crankcase. Permissible piston protrusion 0.765 ~ 1.055 mm Measure at both ends of axial direction. SENSOR CONTROL FUEL COOLING LUB EXHAUST INTAKE HOUSING ASSY
48 02 Special Tools and Equipment Name and Part Number Application Y99220122B Piston protrusion measuring jig Y99220172B Piston insertion jig