42
02
PISTON AND CONNECTING ROD
1. No.1 compression ring
3. Oil ring
2. No.2 compression ring
Description
Cylinder bore diameter
Piston outer diameter (D1)
Clearance between bore and piston
Piston cooling gallery
Pin offset
ENG
φ 86.2 (0~0.018) mm
φ 86.133 (±0.009) mm
74
Applied
0.15 mm (Thrust)
Compression ratio
17.5 : 1
Length of piston pin
71.2 mm
Material of top ring / coating
Tightening torque of connecting rod bolt
Permissible weight difference of connecting rod
Steel / Gas nitride
40 ± 5.0 Nm, 90° + 10°
4g
Thickness of connecting rod bearing (Red)
1.806 ~ 1.809 mm
Thickness of connecting rod bearing (Yellow)
1.809 ~ 1.812 mm
Thickness of connecting rod bearing (Blue)
1.812 ~ 1.815 mm
ENGINE HOUSING
ACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
02
43
GENERAL
PISTON RING
1. No.1 compression ring
2. No.2 compression ring
ASSY
3. Oil ring
5. Coil spring and oil control ring
COOLING
LUB
EXHAUST I N T A K E
HOUSING
6. Hook spring
FUEL
Replacement of Piston Ring
1. Measure piston ring end gap.
CONTROL
1) Piston ring end gap (mm)
1st groove: 0.20 ~ 0.35
2nd groove: 0.20 ~ 0.35
SENSOR
3rd groove: 0.20 ~ 0.40
2) Clearance between piston ring and piston (mm)
1st compression ring: 0.075 ~ 0.119
2nd compression ring: 0.050 ~ 0.090
3rd oil ring: 0.030 ~ 0.070
3. Install the piston so that “Y” marking on piston head
is facing in the direction of travel. Arrange the piston
ring ends to be 120° apart.
4. Adjust the hook spring joint in the oil ring 180° away
from the ring end.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
ACTYON SM - 2006.03
44
02
CYLINDER INNER DIAMETER AND PISTON SIZE
(Unit : mm)
Code
Used piston
Cylinder Diameter
Piston Diameter
A
A or X
86.200 ~ 86.206
86.124 ~ 86.130
X
A, B or X
86.206 ~ 86.212
86.129 ~ 86.137
B
B or X
86.212 ~ 86.218
86.136 ~ 86.142
+5
+5
86.250 ~ 86.260
86.167 ~ 86.181
+ 10
+ 10
86.300 ~ 86.310
86.217 ~ 86.231
ENGINE HOUSING
ACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
02
45
GENERAL
DISASSEMBLY AND REASSEMBLY
EXHAUST I N T A K E
HOUSING
ASSY
1. Install the compression ring and oil ring on the piston
with a special tool.
Arrange the piston ring ends to be 120° apart.
NOTICE
• Install the No.1 and No.2 pistons so that “Y” marking on piston head is facing upward.
LUB
• No.1 piston ring is thicker than No.2 piston ring.
• Arrange the oil ring end to opposite position of current ring end.
COOLING
• Oil ring is not directional.
• Make sure that the piston ring end is not aligned to
axial direction and lateral direction.
0.20 ~ 0.35 mm
2nd groove
0.20 ~ 0.35 mm
3rd groove
0.20 ~ 0.40 mm
CONTROL
1st groove
FUEL
2. Check the clearance of piston oil ring and compression
ring with a thickness gauge and adjust if necessary.
SENSOR
Piston ring end play (mm)
1st groove: 11.0 mm
2nd groove: 10.5 mm
3rd groove: 7.0 mm
3. Check the clearance of piston rings with a thickness
gauge and adjust if necessary.
No.1 compression ring
0.075 ~ 0.119 mm
2nd compression ring
0.050 ~ 0.090 mm
3rd oil ring
0.040 ~ 0.080 mm
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
ACTYON SM - 2006.03
46
02
4. Fit the piston onto connecting rod so that the
marking on piston crown and locking slot are facing
to straight ahead direction.
NOTICE
• Install the piston so that the piston recess (marking)
or the stamped surface of connecting rod is facing
to straight ahead direction.
5. Lubricate piston pin and push in by hand.
NOTICE
• Do not heat up the piston.
6. Place new snap rings into the grooves.
NOTICE
• The snap rings should be replaced with new one.
7. Lubricate the cylinder bore, connecting rod bearing
journals, connecting rod bearing shells and pistons.
8. Push piston into the cylinder with a wooden stick.
9. Insert connecting rod bearing shells.
NOTICE
• The upper and lower connecting rod bearings have
same appearance. Therefore, make sure to check
the part number before replacing them.
• Install bearing rod bearing cap so that the retaining lugs are on the same side of the connecting rod
bearing.
ENGINE HOUSING
ACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
02
47
7.1 mm
EXHAUST I N T A K E
HOUSING
ASSY
Limit “C”
GENERAL
10. Measure stretch shaft diameter of the connecting
rod bolts.
11. Lubricate the new connecting rod bolts and tighten.
Installation Notice
40 ± 5.0 Nm,
90° + 10°
LUB
Tightening torque
• End play of connecting rod cap
0.5 ~ 1.5 mm
COOLING
Specified value
0.765 ~ 1.055 mm
CONTROL
Permissible piston
protrusion
FUEL
12. Position piston to TDC and measure the distance
between piston and mating surface of crankcase.
SENSOR
• Measure at both ends of axial direction.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
ENGINE HOUSING
ACTYON SM - 2006.03
48
02
Special Tools and Equipment
Name and Part Number
Application
Y99220122B
Piston protrusion measuring jig
Y99220172B
Piston insertion jig
ENGINE HOUSING
ACTYON SM - 2006.03
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN