CYLINDER BLOCK REPLACEMENT

PROCEDURE

1. REPLACE STRAIGHT PIN

   
   

   1. Using a plastic hammer, tap in new straight pins to the cylinder block sub-assembly.

      

      *a	Front Side	*b	Rear Side
      *c	Top Side	*d	Bottom Side
      *e	RH Side	*f	23 mm (0.906 in.)
      *g	6 mm (0.236 in.)	*h	11 mm (0.433 in.)
      *i	9 mm (0.354 in.)	-	-

      Standard Protrusion Height
      Item Specified Condition Pin (A) 23 mm (0.906 in.) Pin (B) 6 mm (0.236 in.) Pin (C) 11 mm (0.433 in.) Pin (D) 9 mm (0.354 in.)

2. REPLACE STUD BOLT

   
   

   1. Using E8 and E10 "TORX" socket wrenches, install the stud bolts.

      

      *a	Front Side	*b	LH Side
      *c	12 mm (0.472 in.)	*d	52 mm (2.05 in.)
      *e	23 mm (0.906 in.)	*f	15 mm (0.591 in.)
      *g	40 mm (1.57 in.)	-	-

      Torque:

      Bolt (A)

      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Bolt (B)

      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

3. REPLACE CONNECTING ROD SMALL END BUSH

   
   

   1. 

      Using SST and a press, press out the connecting rod small end bush.

      SST

      09222-30010

   2. 

      *a

      Oil Hole

      Align the oil hole of a new connecting rod small end bush with the oil hole of the connecting rod.

   3. 

      Using SST and a press, install the connecting rod small end bush.

      SST

      09222-30010

   4. 

      Using a pin hole grinder, hone the connecting rod small end bush to obtain the standard oil clearance between the connecting rod small end bush and piston pin.

      Standard Oil Clearance
      0.001 to 0.007 mm (0.0000394 to 0.000276 in.)

   5. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

      Tech Tips

      Check that the piston pin fits at a normal room temperature.