Connecting Rod: Testing and Inspection

ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod alignment.
1. Check for bend as shown in the illustration.
Maximum bend: 0.050 mm (0.0020 inch) per 100.000 mm (3.94.00 inch).
If bend is greater than maximum, replace the connecting rod assembly.





2. Check for twist as shown in the illustration.
Maximum twist: 0.150 mm (0.0059 inch) per 100.000 mm (3.9400 inch).
3. If twist is greater than maximum, replace the connecting rod assembly.





PISTON PIN BUSHING OIL CLEARANCE
1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing as shown.
Bushing inside diameter: 22.0115-22.014 mm (0.8663-0.8667 inch).





2. Using a micrometer, measure the piston pin diameter.
Piston pin diameter: 21.997-22.006 mm (0.8660-0.8664 inch).
3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement.
Standard oil clearance: 0.005-0.011 mm (0.0002-0.0004 inch).
Maximum oil clearance: 0.050 mm (0.0020 inch).
4. If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.





ROD BOLT
1. Using vernier calipers, measure the tension portion of the connecting rod bolt.
Standard diameter: 7.200-7.300 mm (0.2835-0.2874 inch).
Minimum diameter: 7.00 mm (0.2756 inch).
2. If the diameter is less than minimum, replace the bolt.





THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth.
Standard thrust clearance: 0.160-0.290 mm (0.0063-0.0138 inch).
Maximum thrust clearance: 0.35 mm (0.0138 inch).
2. If the thrust clearance is greater than maximum, replace the connecting rod assembly(s) and/or the crankshaft.
Connecting rod thickness: 22.880-22.920 mm (0.9008-0.9024 inch).