Table of Contents
Assembly
1) Check connecting rod bolts for deformation referring
to "Connecting Rod Bolt" under "Crank Pin and
Connecting Rod Bearings Inspection".
If connecting rod bolt is deformed, use new
connecting rod in next step.
2) Install piston pin to piston (1) and connecting rod (2):
a) After applying engine oil to piston pin and piston
pin holes in piston and connecting rod.
b) Fit connecting rod as shown in the figure.
c) Insert piston pin to piston and connecting rod.
d) Install piston pin circlips (3).
NOTE
Circlip should be installed with its cut part
facing as shown in the figure. Install so that
circlip end gap comes within such range as
indicated by arrow.
3) Install piston rings to piston:
• As indicated in the figure, 1st and 2nd rings have
"T" mark respectively. When installing these piston
rings to piston, direct marked side of each ring
toward top of piston.
• 1st ring (1) differs from 2nd ring (2) in thickness,
shape and color of surface contacting cylinder
wall.
Distinguish 1st ring from 2nd ring by referring to
the figure.
• When installing oil ring (3), install spacer first and
then two rails.
4) After installing three rings (1st, 2nd and oil rings),
distribute their end gaps as shown in the figure.
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
Cylinders, Pistons and Piston Rings Inspection
Cylinder
• Inspect cylinder walls for scratches, roughness, or
ridges which indicate excessive wear. If cylinder bore
is very rough or deeply scratched, or ridged, rebore
cylinder and use oversize piston.
• Using a cylinder gauge (1), measure cylinder bore in
thrust and axial directions at two positions ("a" and
"b") as shown in the figure.
If any of the following conditions is noted, rebore
cylinder.
1) Cylinder bore dia. exceeds limit.
2) Difference of measurements at two positions
exceeds taper limit.
I2RH0B140115-01
3) Difference between thrust and axial measurements
exceeds out-of-round limit.
Cylinder bore diameter
Standard: 78.000 – 78.014 mm (3.0709 – 3.0714
in.)
Limit: 78.114 mm (3.073 in.)
Cylinder taper and out-of-round
Limit: 0.10 mm (0.004 in.)
NOTE
If any one of four cylinders has to be rebored,
rebore all four to the same next oversize.
This is necessary for the sake of uniformity
and balance.
I2RH0B140116-01
Engine Mechanical:
1D-38
IYSQ01142102-01
4. Oil ring upper rail gap
5. Oil ring lower rail gap
S3RH0A1406038
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