CYLINDER BLOCK REPLACEMENT

PROCEDURE

  1. REPLACE RING PIN

    Note:

    It is not necessary to remove the ring pins unless they are being replaced.

    1. A151025C05

      *a

      Upper Side

      *b

      Width

      *c

      Height

      *d

      Protrusion Height

      Using a plastic-faced hammer, tap in the ring pins.

      Table 1. Standard Ring Pin

      Item

      Height

      Width

      Protrusion

      Ring Pin

      14.3 to 14.7 mm (0.563 to 0.579 in.)

      12.9 to 13.0 mm (0.508 to 0.512 in.)

      7.5 to 8.5 mm (0.295 to 0.335 in.)

  2. REPLACE STRAIGHT PIN

    Note:

    It is not necessary to remove the straight pins unless they are being replaced.

    A196604C02

    *a

    Front Side

    *b

    Rear Side

    *c

    Lower Side

    *d

    LH Side

    *e

    Protrusion Height

    -

    -

    1. Using a plastic-faced hammer, tap in the straight pins.

      Standard Straight Pin

      Item

      Height

      Width

      Protrusion

      Pin A

      36 mm (1.42 in.)

      10 mm (0.394 in.)

      18.5 to 19.5 mm (0.728 to 0.768 in.)

      Pin B

      12 mm (0.472 in.)

      4 mm (0.157 in.)

      5.0 to 7.0 mm (0.197 to 0.276 in.)

      Pin C

      22 mm (0.866 in.)

      10 mm (0.394 in.)

      11 to 13 mm (0.433 to 0.512 in.)

      Pin D

      18 mm (0.709 in.)

      8 mm (0.315 in.)

      8.0 to 10.0 mm (0.315 to 0.394 in.)

      Pin E

      12 mm (0.472 in.)

      4 mm (0.157 in.)

      5.0 to 6.0 mm (0.197 to 0.236 in.)

  3. REPLACE STUD BOLT

    Note:

    If the stud bolt is deformed or the threads are damaged, replace it.

    Tip:

    There are 2 installation types for the No. 1 ventilation case.

    This procedure is for type A.

    1. Using an E6 "TORX" socket wrench, remove the stud bolts.

    2. A151026C04

      *a

      LH Side

      Using an E6 "TORX" socket wrench, install the stud bolts as shown in the illustration.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  4. REPLACE CONNECTING ROD SMALL END BUSH

    1. A132154N08

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

      09222-30010

    2. A132157C08

      *a

      Oil Hole

      Align the oil holes of a new connecting rod small end bush and the connecting rod.

    3. A132154N09

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

      09222-30010

    4. A132159

      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

      -0.002 to 0.004 mm (-0.0000787 to 0.000157 in.)

    5. A132160

      Coat the piston pin with engine oil. Push the piston pin into the connecting rod with your thumb to check that the piston pin fits at normal room temperature.