Connecting Rods, Pistons & Cylinder Sleeves

MST-H1-EN-1 (fig.13) as follows : c)Before installing sleeve, check the counter bore at top and sealing ring groove at the bottom are clean and free from foreign material. All sleeves should enter crankcase bores full depth and should free to rotate by hand (without sealing ring). d)Check the sleeves for scoring or signs of corrosion.

•Insert the sleeve puller from the top of the crankcase (fig.14).

•Fix the thrust plate sides at lower portion of cylinder sleeve. The bigger side of thrust plate is suitable for DI Engine.

•Position the bracket on top of the crankcase and tighten the nut over the bracket of puller bar, by rotating handle, the sleeve will be pulled out while tightening the nut.

NOTE: The cylinder head gasket forms the upper cylinder sleeve seal, and excessive sleeve stand out will result in coolant leakage. To test lower sealing rings for proper installation, fill crank case water jacket with cold water and check for leaks near bottom of sleeves.

3.INSTALLATION a)Dip each cylinder sleeve packing ring in a soap solution and install it in the groove in the crankcase bore. b)Coat bottom of each sleeve with soap solution and press the sleeve into the crankcase bore. c)Check from below to ensure that the packing rings have not been sheared or pushed out of position. d)Check the cylinder sleeve protrusion (Fig.11) to specifications. The top face of the sleeve can be 0.05 mm above the cylinder block face or 0.03 mm below the cylinder block face. To ensure the above dimension, the cylinder sleeve and the cylinder block should be matched.

NOTE: Weights refer to complete connecting rods with bushing, bearing cap and bolts but less securing wire and without bearing halves.

NOTE: Check cylinder sleeve protrusion according to checking sleeve protrusion procedure given below : e)Install the piston assemblies.

1.Place the sleeve in the crankcase with out ‘O’ Ring.

2.Clamp the sleeve down using four holding adapters/plate shown in fig.12 place sleeve holding plate locally.