FE02-0276b

6.

Remove the oil ring.

FE02-0277b

7.

Remove the piston pin circlip at both ends.

FE02-0278b

8.

With a special tool GL301-016 remove the piston pin.

Engine

Engine Mechanical System JL4G18-D

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FE02-0279b

9.

Disassemble  connecting  rod,  piston  pin  and  piston  are
shown in the graphic.

Installation Procedure:

FE02-0279b

1.

Install piston pin, connecting rod and piston.

Note

During  installation,  connecting  rod  bearings  mark
and  the  piston  mark  should  face  the  same  the
direction.

FE02-0281b

2.

Install the piston pin circlip.

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Engine Mechanical System JL4G18-D

Engine

FE02-0282b

3.

Confirm normal movements between the piston and rod
without any interference.

4.

Check piston pin and connecting rod clearance.

Standard Value:0.005-0.011 mm (Metric) 0.0002-0.0004
in (US English)

5.

Check the piston and piston pin clearance.

Standard  Value:  0.005-(-0.001)  mm  (Metric)  0.0002-
(-0.00003) in (US English)

6.

Install the oil ring.

FE02-0283b

7.

Install the oil ring lower ring combination.

FE02-0284b

8.

Install the oil ring upper ring combination.

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Engine Mechanical System JL4G18-D

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FE02-0285b

9.

Install the second air ring.

Note

The side with letters should face the top.

FE02-0286b

10. Install first gas ring.

Note

The chamfered side should face the top.

11. Apply the engine oil to the connecting rod bearings and

install the connecting rod journal and the bearing cap.

12. Install  the  connecting  rod  to  the  crankshaft.  Check

whether  the  bearing  clearance  is  acceptable.  Refer  to

2.6.1.2

 

Mechanical System Specification

.

Standard Value: 0.020-0.044 mm (Metric) 0.0007-0.0017
in (US English)

13. Install the piston rod components.

2.6.8.20 Valve Clearance Adjustments

FE02-0287b

1.

Remove the engine plastic shield. Refer to 

2.6.8.1

 

Plastic

Engine Shield Replacement

.

2.

Remove  the  ignition  coil.  Refer  to 

2.10.8.3

 

Ignition  Coil

Replacement

.

3.

Remove the cylinder head cover. Refer to 

2.6.8.2

 

Cylinder

Head Cover Replacement

.

4.

Remove the timing chain cover, rotate the crankshaft so
that  cylinder  No.1  is  at  TDC  position.  Refer  to

2.6.8.9

 

Timing Chain Cover Replacement

.

5.

Check  valve  clearance.  Use  the  plug  gage  to  measure
valve clearance value, as arrows shown in the graphic and
record the valve location and tolerance that exceeds the
tolerance.

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Engine