R9M Bottom Engine Crankshaft Details

3/21/24, 9:28 PM Piston, Connecting Rod, and Bearing Replacement
Piston, Connecting Rod, and Bearing ReplacementENGINE

MECHANICAL - 1.6L DIESEL
Special Tools
EN-301 Measuring Bridge

EN-470-B Angular Torque Wrench
GE-571-B Dial Gauge
EN-49271 Engine Stand
EN-51241 Timing Pin
Equivalent regional tools: Special Tools
Removal Procedure
Warning: Refer to Disposing of Used Fluids, Lubricants, and Contaminated Materials Warning .
Warning: Refer to Fuel Escape Warning .
Caution: Refer to New Blanking Plugs Caution .
Note: Pistons are matched by height class. If replacing a piston, all 4 pistons must be replaced.
Note: Connecting rods are matched by weight. If replacing a connecting rod, all 4 connecting
rods must be replaced.
1. Engine Assembly » Remove — Engine Replacement

2. Install the engine assembly to the EN-49271 engine stand. Engine Mounting to Stand .
3. Cylinder Head » Remove — Cylinder Head Replacement
4. Lower Crankcase » Remove — Lower Crankcase Replacement
5. Oil Pump » Remove — Oil Pump Replacement
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6. Oil Pump Drive Chain (1) » Remove

7. Oil Pump Drive Chain Sprocket (2) » Remove
8. Remove the EN-51241 timing pin from the engine block.
9. Mark the cylinder number on the connecting rod and the connecting rod cap with a scribe,
paint stick or permanent marker.
Note: No.1 cylinder is at the timing end of the engine.
10. Remove the bolts (1), then remove the connecting rod cap (2) from the No.1 cylinder
connecting rod (3).
Note: Keep the connecting rod, cap and bolts together.
11. Use a suitable tool to push the piston and connecting rod (3) out of the cylinder bore.
12. Repeat the operation for the remaining 3 cylinders.
13. Remove the bearing shells (4) from the connecting rod (5) and connecting rod cap.
14. Secure the connecting rod (5) in a soft-jawed vice.
15. Using a suitable tool, remove the piston pin retainers (1) from the piston (3).
Note: Observe the orientation of the piston and connecting rod for installation purposes.
16. Remove the piston pin (2) and piston (3) from the connecting rod (5).
17. Repeat the operation for the remaining 3 pistons.
18. Clean and inspect the piston and connecting rod assemblies. Piston, Connecting Rod, and
Bearing Cleaning and Inspection .
Note: Only remove the crankshaft if necessary.
19. Inspect the 4 connecting rod journals on the crankshaft. Crankshaft and Bearing Cleaning and
Inspection .
20. Clean and inspect the engine block. Engine Block Cleaning and Inspection .
Installation Procedure
1. Apply clean engine oil to the bearing shells (1) and install to the connecting rod (2) and
connecting rod cap (3).
2. Measure the connecting rod bearing play. Piston, Connecting Rod, and Bearing Cleaning and
Inspection
3. Center the bearing shell (2) on the connecting rod (1) using a suitable feeler gauge (3).
A = 2 mm (0.79 in) ± 0.1 mm (0.004 in)
Caution: Use a piston ring expander to install the piston rings. The rings may be damaged if
expanded more than necessary.
Note: Install the piston rings on the same axis as the piston pin as shown.
5. If replacing the piston, use a suitable tool to install the NEW piston rings (1).
6. Secure the connecting rod (4) in a soft-jawed vice.

7. Apply clean engine oil to the piston pin (2).
8. Install the piston (3) and piston pin (2) to the connecting rod (4).
Caution: Install the piston pin retainers correctly in the retaining groove during assembly in
order to avoid engine damage.
9. Using a suitable tool, install the piston pin retainers (1) to the piston (3).
11. Apply clean engine oil to the 4 connecting rod journals on the crankshaft.
12. Install the No.1 piston.

12.1. Apply clean engine oil to the piston rings, piston, inner cylinder bore surface and a
piston ring compressor (1) (commercially available).
Note: Do not over-tighten the piston ring compressor.
12.2. Install the piston ring compressor (1) to the piston and compress the piston rings.
Note: Ensure that the V on the piston head faces towards the engine flywheel end.
12.3. Install the piston and connecting rod to the No.1 cylinder bore.
12.4. Using a suitable tool, gently tap the piston downwards, until the connecting rod
contacts the crankshaft journal.
Caution: Refer to Fastener Caution .

Note: Do not tighten the bolts at this stage.
13. Install the No.1 cylinder connecting rod cap (2) and the NEW bolts (1) to the connecting rod
(3).
15. Tighten the 8 bolts (1) to 25 Nm (18 lb ft) plus 110 degrees ± 4 degrees using the EN-
470-B wrench.
Note: Ensure the piston and engine block surfaces are free of carbon, gasket material, or
other objects that may give an incorrect measurement.
16. Measure the piston protrusion.
16.1. Place the EN-301 measuring bridge (1) with the GE-571-B dial gauge (2) on the engine
block.
16.2. Position the pointer of the GE-571-B dial gauge (2) on the engine block.
16.3. Set the pointer to (0) ZERO.
Note: The pointer must be positioned on the center line of the engine block.
16.4. Position the pointer of the GE-571-B dial gauge (2) on the piston head.
16.5. Use a wrench to rotate the crankshaft clockwise until the piston is at top dead centre
(TDC) on the compression stroke.
16.6. Record the readings.
17. Replace the piston if measurements are not within the limit, refer to Engine Mechanical
Specifications .
19. Screw the EN-51241 timing pin into the engine block.
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20. Oil Pump Drive Chain Sprocket (2) » Install

21. Oil Pump Drive Chain (1) » Install
22. Oil Pump » Install — Oil Pump Replacement
23. Lower Crankcase » Install — Lower Crankcase Replacement
24. Cylinder Head » Install — Cylinder Head Replacement
25. Remove the engine assembly from the EN-49271 engine stand. Engine Removal from Stand .
26. Engine Assembly » Install — Engine Replacement
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3/21/24, 9:28 PM Piston, Connecting Rod, and Bearing Replacement

Piston, Connecting Rod, and Bearing ReplacementENGINE

EN-301 Measuring Bridge

Equivalent regional tools: Special Tools

Warning: Refer to Fuel Escape Warning .

Caution: Refer to New Blanking Plugs Caution .

1. Engine Assembly » Remove — Engine Replacement

6. Oil Pump Drive Chain (1) » Remove

6. Secure the connecting rod (4) in a soft-jawed vice.

12. Install the No.1 piston.

Caution: Refer to Fastener Caution .

20. Oil Pump Drive Chain Sprocket (2) » Install

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