Piston, Pin, and Connecting Rod Replacement

Disassembly


1.Remove the piston from the engine block.

2.Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B).

NOTE: Take care no to damage the ring grooves.

 

3.Remove both snap rings (A). Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection.

4.Remove the piston pin.

Inspection


1.Measure the diameter of the piston pin.

Piston Pin Diameter 
Standard (New): 29.995-30.000 mm
(1.1809-1.1811 in.)
 
Service Limit: 29.985 mm (1.1805 in.) 

 

2.Zero the dial indicator to the piston pin diameter.

 

3.Measure the piston pin-to-piston clearance.

Piston Pin-to-Piston Clearance 
Standard (New): 0.005-0.016 mm
(0.0002-0.0006 in.)
 
Service Limit: 0.026 mm (0.0010 in.) 

 

4.Measure the piston pin-to-connecting rod clearance.

Piston Pin-to-Connecting Rod Clearance 
Standard (New): 0.012-0.025 mm
(0.0005-0.0010 in.)
 
Service Limit: 0.035 mm (0.0014 in.) 

 

Reassembly


1.Install a new piston pin snap ring (A).

 

2.Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.

3.Assemble the piston (A) and connecting rod (B) with the mark (C) and the embossed mark (D) on the same side. Install the piston pin (E).

 

 

4.Install the remaining new snap ring (F).

5.Turn the snap rings in the ring grooves until the end gaps are positioned at the bottom of the piston.