Mark the cylinder number on the side of the connecting rod big end as a guide for reassembly.

The special tool, Piston pin setting tool (MD998780), consists of the elements shown in the drawing.

1. Insert the tool element, Push rod, into the piston from the front mark side (notched side), then attach the tool element, Guide C, to the push rod.

2. Place the piston and connecting rod assembly on the tool element, Base, with the front mark facing up.

3. Use a press to remove the piston pin.
NOTE: Keep the disassembled pistons, piston pins and connecting rods cylinder by cylinder.

1. When replacing a piston, check the cylinder bore size mark stamped at the indicated location on the cylinder block and select an appropriate replacement piston using the following table.

Cylinder bore size mark	Piston size mark
I	A
II	No mark
III	C



NOTE: The piston size mark is located on the piston top surface.

2. Measure the following dimensions:
• A: Piston pin insertion hole length
• B: Distance between piston bosses
• C: Piston pin length
• D: Connecting rod small end width

3. Obtain dimension L from the measurements using the following formula.
   L =[(A - C) - (B - D)]÷ 2

4. Insert the tool element, Push rod, into the piston pin and attach the tool element, Guide A (21.9 mm) to the push rod end.

5. Assemble the connecting rod with the piston with their front marks facing in the same direction.

6. Apply engine oil to the outside surface of the piston pin.

7. Insert the assembly of piston pin, Push rod and Guide A (put together in step 3.) into the piston pin holes from the front marked side of the piston.

8. Screw the guide B into the guide A until the gap between both guides amounts the value L obtained in step 2 plus 3 mm.

9. Place the piston and connecting rod assembly onto the tool element, Piston setting base, with the front marks facing up.

10. Install the piston pin using a press. If the required press force is less than the standard value, replace the piston and piston pin assembly or the connecting rod, or both.
Standard value: 7,350 - 17,100 N

1. Fit the oil ring spacer into the piston ring groove.

 CAUTION
Use of ring expander to expand the side rail end gap can break the side rail, unlike the other piston rings.

2. Install the upper side rail, then the lower side rail.
   To install each side rail, first fit one end of the rail into the piston groove, then press the remaining portion progressively into position by finger as shown in the drawing.
NOTE: Each of the spacers and the side rails (new) has an identification color as follows:


Size	Color mark
Standard	No mark
0.50 mm oversize	Red
1.00 mm oversize	Yellow

3. Make sure that the installed side rails move smoothly in either direction.

Using a piston ring expander, install the piston rings with their identification marks facing up (toward the piston head).

1. When replacing the connecting rod bearing, select a bearing of the size appropriate for the crankshaft pin diameter in accordance with the crankshaft pin and connecting rod bearing matching table shown below.

2. Crankshaft pin diameter marks are stamped in the indicated locations.

3. Connecting rod bearing identification mark is stamped in the indicated location on each bearing.

Crankshaft pin		Connecting rod bearing
Identification mark	Diameter mm	Identification mark
I	44.995 - 45.000	1
II	44.985 - 44.995	2
III	44.980 - 44.985	3

4. <Bearing selection example>
   If the crankshaft pin diameter mark is “I,” select a bearing marked “1.”
   If the crankshaft pin diameter mark is illegible, measure the pin diameter and select a bearing with the mark corresponding to the measurement.

5. Install the upper and lower halves of the selected bearing on the connecting rod big end and cap, respectively.

2. Align the end gaps of the piston rings and oil ring (side rail and spacer) as shown in the drawing.

3. Insert the piston and connecting rod assembly from the top of cylinder with the front mark notch on the head toward the camshaft sprocket.

4. Use a piston ring band to hold the piston rings compressed when inserting the piston and connecting rod assembly into the cylinder. Do not strike the assembly with a large force. Doing so could break the piston rings and crank pin.

1. Install the bearing cap on the connecting rod while aligning the marks made during disassembly. If the connecting rod is new and has no alignment mark, assemble it with the cap such that both bearing locating notches are on the same side as shown in the drawing.

2. Make sure that the thrust clearance of the connecting rod big end is proper.
Standard value: 0.10 - 0.25 mm

Limit: 0.4 mm

5. Make a paint mark on the head of each nut.

6. Make a paint mark on the bolt at a point 90° to 94° away in the tightening direction from the paint mark made on the nut.

7. Turn the nut 90° to 94° to bring the mark on the nut into alignment with that on the bolt.
 CAUTION
• If the tightening angle is less than 90°, adequate tightness could not be assured.
• If the tightening angle exceeds 94°, loosen the nut completely and then perform the tightening procedure again beginning with the first step.