S-80
03-M Series, WSM
DIESEL ENGINE
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing. If it still exceeds the allowable limit, replace the piston
pin.
W1031982
Replacing Connecting Rod Small End Bushing
(When removing)
1. Press out the used small end bushing using a small end bushing
replacing tool. (See page
“SPECIAL TOOLS”
.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Using a small end bushing replacing tool, press in a new bushing
taking due care to see that the connecting rod oil hole matches
the bushing hole.
W1032140
Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (the least worn
out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the ring.
W1032246
Oil clearance between
piston pin and small end
bushing
Factory spec.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
Allowable limit
0.15 mm
0.0059 in.
Piston pin O.D.
Factory spec.
25.002 to 25.011 mm
0.98433 to 0.98469 in.
Small end bushing I.D.
Factory spec.
25.025 to 25.040 mm
0.98524 to 0.98583 in.
(A) When removing
(B) When installing
Top ring
Factory
spec.
D1503-M
0.20 to 0.35 mm
0.0079 to 0.0138 in.
D1703-M
D1803-M
V2203-M
V2403-M
0.20 to 0.40 mm
0.0079 to 0.0157 in.
Allowable limit
1.25 mm
0.0492 in.
Second ring
Factory spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
Oil ring
Factory spec.
0.25 to 0.45 mm
0.0098 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
KiSC issued 08, 2012 A
