Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play :
0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in)
If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance, replace the crankshaft.
Check the connecting rod bearing oil clearance.
Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
Remove the 2 connecting rod cap bolts.
Remove the connecting rod cap and lower bearing.
Clean the crank pin journal and bearing.
Place a plastigage across the crankshaft pin journal.
Reinstall the lower bearing and cap, and tighten the bolts.
Tightening torque :
11 ~ 15 N.m (1.1 ~ 1.5 kgf.m, 8.0 ~ 10.8 lb-ft) + 88 ~ 92°
Do not turn the crankshaft.
Always use new connecting rod cap bolts. Connecting rod cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Remove the 2 bolts, connecting rod cap and lower bearing.
Measure the plastigage at its widest point.
Standard oil clearance :
0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in)
If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark (Refer to connecting rod bearing selection table) Recheck the oil clearance.
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
If the plastigage shows the clearance is still incorrect, try the next lager or smaller bearing. (Refer to connecting rod bearing selection table Recheck the oil clearance.
If the proper clearance cannot be obtained by using the appropriate lager or smaller bearings, replace the crankshaft and start over.
If the alignment marks are unreadable because of an accumulation of grease or grime, don't clean with a wire or abrasive cleaner. Clean only with correct cleaning solvent or detergent.
Connecting Rod Mark Location
Discrimination Of Connecting Rod
Grade | Mark | Connecting Rod Big-end Inner Diameter |
0 | A | 42.000 ~ 42.006 mm (1.6535 ~ 1.6540 in) |
1 | B | 42.006 ~ 42.012 mm (1.6537 ~ 1.6540 in) |
2 | C | 42.012 ~ 42.018 mm (1.6540 ~ 1.6542 in) |
Crankshaft Pin Journal Mark Location
Discrimination Of Crankshaft Pin Journal
Class | Mark | Crankshaft Pin Journal outer Diameter |
I | 1 | 38.966 ~ 38.972 mm (1.5340 ~ 1.5343 in) |
II | 2 | 38.960 ~ 38.966 mm (1.5338 ~ 1.5340 in) |
III | 3 | 38.954 ~ 38.960 mm (1.7698 ~ 1.7701 in) |
Connecting Rod Bearing Mark Location
Discrimination Of Connecting Rod Bearing
Grade | Color | Connecting Rod Bearing Thickness |
A | Blue | 1.514 ~ 1.517 mm (0.0596 ~ 0.0597 in) |
B | Black | 1.511 ~ 1.514 mm (0.0595 ~ 0.0596 in) |
C | None | 1.508 ~ 1.511 mm (0.0594 ~ 0.0595 in) |
D | Green | 1.505 ~ 1.508 mm (0.0593 ~ 0.0594 in) |
E | Yellow | 1.502 ~ 1.505 mm (0.0591 ~ 0.0593 in) |
Select the bearing by using selection table.
Connecting Rod Bearing Selection Table
Connecting Rod Bearing | Connecting Rod Mark | |||
0(A) | 1(B) | 2(C) | ||
Crank shaft pin journal mark | I(1) | E(Yellow) | D(Green) | C(None) |
II(2) | D(Green) | C(None) | B(Black) | |
III(3) | C(None) | B(Black) | A(Blue) | |
Clean the piston
Using a gasket scraper, remove the carbon from the piston top.
Using a groove cleaning tool, clean the piston ring grooves.
Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
The standard measurement of the piston outside diameter is taken 30.0mm (1.21in) from top land of the piston.
Standard diameter :
71.970 ~ 72.000 mm (2.8334 ~ 2.8346 in)
Check the cylinder bore size code on the cylinder block.
Discrimination of cylinder bore size
Grade | Size code | Cylinder Bore inner Diameter |
a | A | 72.00 ~ 72.01 mm (2.8346 ~ 2.8350 in) |
b | B | 72.01 ~ 72.02 mm (2.8350 ~ 2.8354 in) |
c | C | 72.02 ~ 72.03 mm (2.8354 ~ 2.8358 in) |
Check the piston size code (A) and the front mark (B) on the piston top face.
Discrimination Of Piston Outer Diameter
Grade | Size code | Piston Outer Diameter |
a | A | 71.970 ~ 71.980 mm (2.8334 ~ 2.8338 in) |
b | B | 71.980 ~ 71.990 mm (2.8338 ~ 2.8342 in) |
c | C | 71.990 ~ 72.000 mm (2.8342 ~ 2.8346 in) |
Select the piston related to cylinder bore class.
Clearance :
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)
Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance :
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring groove width
No.1 : 1.035 ~ 1.05 mm (0.0407 ~ 0.0413 in)
No.2 : 1.23 ~ 1.25 mm (0.0484 ~ 0.0492 in)
Oil ring : 2.01 ~ 2.025 mm (0.0791 ~0.0797 in)
Piston ring width
No.1 : 0.97~ 0.985 mm (0.0381 ~ 0.0387 in)
No.2 : 1.17 ~ 1.19 mm (0.0460 ~ 0.0468 in)
Oil ring : 1.90 ~ 1.96 mm (0.0748 ~ 0.0772 in)
Piston ring side clearance
No.1 : 0.05 ~ 0.08 mm (0.0019 ~ 0.0031 in)
No.2 : 0.04 ~ 0.08 mm (0.0015 ~ 0.0031 in)
Oil ring : 0.05 ~ 0.125 mm (0.0020 ~0.0049 in)
If the clearance is greater than maximum, replace the piston.
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits. If the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
No.1
0.13 ~ 0.25 mm (0.0051 ~ 0.0098 in)
No.2 : 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in)
Oil ring : 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in)
Measure the diameter of the piston pin.
Piston pin outer diameter :
18.000 ~ 18.003 mm (0.7086 ~ 0.7087 in)
Piston pin hole diameter :
18.013 ~ 18.017 mm (0.7092 ~ 0.7093 in)
Connecting rod small end inner diameter :
17.974 ~ 17.985 mm (0.7076 ~ 0.7080 in)
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance :
0.010 ~ 0.017 mm (0.00039 ~ 0.00067 in)
Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference :
0.015 ~ 0.029 mm (0.0006 ~ 0.0014 in)
