3003 Engine
Markings on the Piston
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| Illustration 1 | g00453417 |
Marks on the connecting rod and piston | |
The pistons and connecting rods are matched to each cylinder. Note the position of each connecting rod and piston for correct assembly.
Identification marks (1) on the connecting rod and the connecting rod cap must align. When the connecting rod is installed correctly, the marks should face the right side of the engine.
Note: Install the pistons from the front of the engine in ascending order.
Note: Be sure that the end gaps of all the piston rings have 120 degrees spacing from each other.
Piston Rings
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| Illustration 2 | g00388210 |
Piston and rings on the 3003 engine | |
The pistons have a flat crown. The piston crown does not have a chamber.
Note: If the piston ring end gap or the ring clearance in the groove is greater than the maximum, replace the piston ring.
(1) Top piston ring
- Shape of top ring ... Barrel face
Note: Install the piston ring with the scribe mark toward the top of the piston.
(2) Intermediate ring
- Shape of intermediate ring ... Taper
Note: Install the piston ring with the scribe mark toward the top of the piston.
(3) Oil control ring
Note: Install the piston ring with the scribe mark toward the top of the piston.
The oil control ring on the 3003 engine has three components: oil control ring (3), spring (5) and latch pin.
Note: When the latch pin is installed in spring (5), ensure that the gap of the latch pin is 180 degrees away from the gap in the spring before you install oil control ring (3) .
(4) Snap ring groove
Note: Use a piston to insert the piston ring square with respect to the cylinder bore. The top surface of the piston ring should be equally distant from the face of the cylinder block at all points before the piston ring end gap is measured.
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| Illustration 3 | g00751702 |
(6) Thickness gauge
(7) Piston ring
- Gap for No. 1 piston ring ... 0.15 to 0.27 mm (0.0059 to 0.0106 inch)
- Service limit for No. 1 piston ring ... 1.0 mm (0.0394 inch)
- Gap for No. 2 piston ring ... 0.12 to 0.24 mm (0.0047 to 0.0094 inch)
- Service limit for No. 2 piston ring ... 1.0 mm (0.0394 inch)
- Gap for oil control ring ... 0.20 to 0.35 mm (0.0079 to 0.0138 inch)
- Service limit for oil control ring ... 1.0 mm (0.0394 inch)
Measure the clearance between the piston ring groove and the piston ring. If the clearance exceeds the service limit, then replace the pistons and the rings.
- Clearance for the No. 1 piston ring ... 0.06 to 0.10 mm (0.0024 to 0.0039 inch)
- Service limit for No. 1 piston ring ... 0.25 mm (0.0098 inch)
- Clearance for No. 2 piston ring ... 0.05 to 0.09 mm (0.0020 to 0.0035 inch)
- Service limit for No. 2 piston ring ... 0.25 mm (0.0098 inch)
- Clearance for the oil control ring ... 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
- Service limit for the oil control ring ... 0.15 mm (0.0059 inch)
Pistons
Diameter of piston
- Standard piston ... 74.9325 to 74.9475 mm (2.9501 to 2.9507 inch)
- Service limit ... 74.7 mm (2.94 inch)
- Diameter of piston skirt ... 74.9325 to 74.9475 mm (2.9501 to 2.9507 inch)
Clearance of the piston to the cylinder wall
- Standard clearance ... 0.0525 to 0.0865 mm (0.0021 to 0.0034 inch)
- Service limit ... 0.25 mm (0.0098 inch)
Piston pin
- Outside diameter ... 20.998 to 21.002 mm (0.8267 to 0.8268 inch)
- Service limit ... 20.98 mm (0.8260 inch)
Clearance between the hole for the piston pin and the piston pin
- Standard clearance ... -0.004 to +0.004 mm (-0.00016 to +0.00016 inch)
- Service limit ... 0.02 mm (0.0008 inch)
3013, 3014, and 3024 Engines
Markings on the Piston
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| Illustration 4 | g00453417 |
Marks on the connecting rod and piston | |
The pistons and connecting rods are matched to each cylinder. Note the position of each connecting rod and piston for correct assembly.
Identification marks (1) on the connecting rod and the connecting rod cap must align. When the connecting rod is installed correctly, the marks should face the right side of the engine.
Note: Install the pistons from the front of the engine in ascending order.
Note: Be sure that the end gaps of all the piston rings have 120 degrees spacing from each other.
Piston Rings
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| Illustration 5 | g00453418 |
Piston rings and the components of the oil control ring for 3013, 3014 and 3024 engines | |
The chamber (2) that is in the top of the piston must face the right side of the engine.
Identification marks (1) on the connecting rod and the connecting rod cap must align. When the connecting rod is installed correctly, the marks should face the right side of the engine.
Note: If the piston ring end gap or the ring clearance in the groove is greater than the maximum, replace the piston ring.
(1) Top piston ring
- Shape of top ring ... Barrel face
Note: Install the scribe mark on the piston ring toward the top of the piston.
(2) Intermediate ring
- Shape of intermediate ring ... Taper
Note: Install the scribe mark on the ring toward the top of the piston.
(3) Oil control ring
Note: Install the scribe mark on the ring toward the top of the piston.
The oil control ring on 3013, 3014 and 3024 engines has three components. The three components of the oil control ring are installed in the following order:
- Expander
- Upper side rail
- Lower side rail
(4) Snap ring groove
(5) Spring
(6) Upper side rail
Install the upper side rail on top of the expander. Place the end of the side rail into the piston groove. Hold this position with the thumb. Refer to Illustration 5. Slide the side rail into position with the other thumb.
(7) Expander
Ensure that the ends of the expander do not overlap.
(8) Lower side rail
The lower side rail is installed on the bottom of the expander. Place the end of the side rail into the piston groove. Hold this position with the thumb. Refer to Illustration 5. Slide the side rail into position with the other thumb.
(9) The gap of side rail (10) and side rail (12) should be a minimum of 30 degrees from the gap of expander (9).
Note: Ensure that the upper side rail and the lower side rail are free to move in both directions. Ensure that the gaps of the expander and both side rails are in the correct positions. Refer to Illustration 5.
Note: Use a piston to insert the piston ring square with respect to the cylinder bore. The top surface of the piston ring should be equally distant from the face of the cylinder block at all points before the piston ring end gap is measured.
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| Illustration 6 | g00695350 |
(13) Feeler gauge
(14) Piston ring
- Gap for No. 1 piston ring ... 0.20 to 0.35 mm (0.0079 to 0.0138 inch)
- Service limit for No. 1 piston ring ... 1.0 mm (0.0394 inch)
- Gap for No. 2 piston ring ... 0.20 to 0.40 mm (0.0079 to 0.0157 inch)
- Service limit for No. 2 piston ring ... 1.0 mm (0.0394 inch)
- Gap for oil control ring ... 0.20 to 0.40 mm (0.0079 to 0.0157 inch)
- Service limit for oil control ring ... 1.0 mm (0.0394 inch)
Measure the clearance between the piston ring groove and the piston ring. If the clearance exceeds the service limit, then replace the pistons and the rings.
- Clearance for the No. 1 piston ring ... 0.07 to 0.11 mm (0.0028 to 0.0043 inch)
- Service limit for No. 1 piston ring ... 0.25 mm (0.0098 inch)
- Clearance for No. 2 piston ring ... 0.04 to 0.08 mm (0.0016 to 0.0032 inch)
- Service limit for No. 2 piston ring ... 0.25 mm (0.0098 inch)
- Clearance for the oil control ring ... 0.02 to 0.06 mm (0.0008 to 0.0024 inch)
- Service limit for the oil control ring ... 0.15 mm (0.0059 inch)
Pistons
Diameter of piston
- Standard piston ... 83.948 to 83.963 mm (3.3050 to 3.3056 inch)
- Service limit ... 83.7 mm (3.295 inch)
- Diameter of piston skirt ... 83.948 to 83.963 mm (3.3050 to 3.3056 inch)
Clearance of the piston to the cylinder wall
- Standard clearance ... 0.038 to 0.072 mm (0.0015 to 0.0028 inch)
- Service limit ... 0.25 mm (0.0098 inch)
Piston pin
- Outside diameter ... 27.996 to 28.000 mm (1.1022 to 1.1024 inch)
- Service limit ... 27.98 mm (1.1016 inch)
Clearance between the hole for the piston pin and the piston pin
- Standard clearance ... -0.001 to +0.007 mm (-0.0004 to +0.0003 inch)
- Service limit ... 0.02 mm (0.0008 inch)