取扱説明書 - TOMEI
Contents
1. ic lt EJ25 26 gt 1 TOMEI EJ25 262. ASSY AN 7
3. mm 6 0 18 lt 0 35 A 4 AN 1 400 R
4. 2 AN A 6 ASSY A ASSY G
5. 2 1 X 1
6. 1 cc cc cc cc Vi E if tt VrVrV 8 A CAUTION E This product has been designed for competition use only and is not to be used on any public roads Mi This product is to be fitted by an experienced professional in a fully equipped workshop Mi This product was specifically designed for the vehicle application as stated above This is not designed and may not be suitable for other cars engines other than stated in this manual If this product kit is installed on any other vehicles engines it may damage this product and or the engine vehicle that it is fitted to E Please do not use high force when removing parts as you may cause damage W This product is to be fitted with the correct tools protective amp safety equipement Failure to do so can lead to possible work hazards E Check that everything has been tightened to the correct torque specifications E Check
7. et EVE mae mm B R RB26 2597 LOBE 1121868111 Boe RB26 2628 1121870111 ee 30 00 EZA 1121865112 EON 11 20 RB26 2628 87 0 1121870112 ee RB25DET 87 0 1113870111 31 00 eee 12 70 NEO6 1114870112 31 00 2556 SR20DET 1131865211 202 nag 1131870211 a 1132865211 a 2138 ee ener 1132870211 T 2163 SR20DE 1134870212 2163 1134875212 2188 5 115285521 2 4G63 52855212 aad 2020 pata 1152860212 2044 ae 1151855212 ae 30 0 22 23 1151860212 2183 EJ25 EJ25 2468 11 1 19 foo EJ25 26 99 75 82997312 30 70 ae 9 50 EZO Ss S 90 23 5 lt 850 4AG 1163815012 eh 1605 pe 1163820012 1625 2JZ 1162865212 ata Se 0 1162870212 3067 2JZ36 1164870212 29 50 ese er 3565 23 00 X RB25DE T NEO 6 RB26 RB25 RB25DE T NEO 6 X 4G63
8. E A C B C D EJ E E A B 5 lt EJ25 26 gt
9. 1737 3 TEL 042 795 8411 FAX 042 799 7851 1737 3 Tsuruma Machida shi Tokyo 194 0004 JAPAN TEL 81 42 795 841 1 main switchboard FAX 81 42 799 7851 http www tomei p co jp 9 00 18 00 If you have any questions in regards to the installation of this product please contact your local authorised Tomei Powered distributor OPEN Monday Friday National holidays and public holidays excluded 09 00 18 00 15 6 M12Y01 3 FORGED PISTON KIT INSTALLATION MANUAL 2015 6 M12Y01 3 24
10. mm 0 045 0 055 EJ 0 035 0 045 10 10mm D R0 3 2 R 400 R
11. 2950 X When you install the Tomei 4G63 Pistons with the stock conrods you ll have to use the Full Floating Bushing on the small ends 13 KIT CONTENTS The following is for each Piston suppplied in the kit Please confirm that each Piston comes with the right parts PISTON PIN SECOND RING PIN CLIP OIL RING 1 SET PRODUCT INFORMATION The following figure is for illustration purposes Actual Piston design may vary Total Piston Height Compression Height Cooling Channel Top Land Top Ring Groove Second Land Second Ring Groove Third Land Oil Ring Groove Piston Ring Details Piston Pin Boss Opposite Thrust Side Piston Pin Hole Skirt Crank Rotation INSTALLATION Please refer to the official workshop service manual from the vehicles manufacturer for detailed assembly informat 1 CYLINDER BORING Always compare diameter of each cylinder bore with the Pistons skirt to confirm the correct clearance CLEARANCE SPECS mm MEASURING THE PISTONS SKIRT DIAMETER Cylinder Bores inner diameter Measurements are to be taken from the lower Piston Skirts outer diameter side of the Piston Trust side 10mm from the Piston clearance specs base of the Skirt Thrust Direction Have the Cylinder block bored to suit Always use a Dummy Head Torque plate when Direction of you have the Cylinder Block bored spindle Once Cylinder Boring has been completed use
12. TOMEI 2015 6 M12Y01 3 The Engine Specialist E 69 INSTALLATION MANUAL FORGED PISTON KIT eee eee 2p English rmi13p TOMEI TOMEI Please carefully read this manual prior to installation Please also refer to the vehicles Service Manual with this Manual After the installation has been completed please keep this manual for future reference If the install was done in a shop please make sure to give this manual to the owner Thank you for purchasing a TOMEI product The TOMEI Piston kit is designed with the engineering skills and experience from our
13. 2 60 70 C 4G63 EJ 3 EJ A E
14. and cannot be used Position the Circlips point in the groove at the position marked A Next place the Circlip in groove at part B whilst pressing the point C with your finger Finally insert the final part into position C and D in order For EJ application ZN CAUTION E Use needle nose Pliers when you work E Do not drop Circlip into the engine when assemble In case of failure please correct Circlip and start over if continue causes to engine damage Pinch a position A using needle nose pliers Place the Circlip in groove while pressing the point B with your finger Confirm that ensure the Circrip place in groove 5 PISTON RING INSTALLATION lt For application except EJ25 26 gt The Oil Rings spacer is built into the piston ring Side Rail Edge groove The side rail of the oil ring is built in an upper amp lower order Position a part of the side rail in the Piston groove hold it in place with your finger amp fit it Do not install with the Piston Ring Expander as the ring side will be damaged Install the Second Ring and Top Ring with the Piston Ring Expander A Position the clock mark side of the ring up Top Ring Clocking Piston Ring Expander Verify that each Piston moves smoothly in either direction Match each Pistons Rings position on each Piston as shown in
15. for any signs of oil leaks and the amount of engine oil in the engine before driving the car When there s insufficient engine oil the engine will have terminal failure WARNING E This product is to be installed when the engine and engine bay is cold Please be sure that all parts are fitted correctly to avoid any possible fire risk hazards SPECIFICATIONS BORE PART OMPRESSION PISTON DISPLACEME CROWN ENGINE MODEL DIA NUMBER HEIGHT PIN DIA NT VOLUME mm cc cc RB26 2597 1121865111 RB28 2738 13 00 RB26 2628 1121870111 RB28 2770 30 00 21 Without Valve Recess RB26 2597 1121865112 RB28 2738 11 2 1121870112 2556 12 70 SR20DET 86 5 1131865211 2021 14 00 87 0 1131870211 2044 l 86 5 1132865211 22 2138 18 00 86 5 87 0 86 5 87 0 87 0 1132870211 2163 R f SR20DE SN 87 0 1134870212 oe 2163 3 50 87 5 1134875212 2188 4G63 855 1152855212 2020 860 1152860212 at y 2044 PO0 4G63 855 1151855212 2158 22 23 860 1151860212 oie 2183 0 EJ25 EJ25 26 99 75 1182997312 30 70 EJ25 2468 41950 emo _ 925 3200 925 37 00 eS 81 5 _625 82 0 2JZ 86 5 1162865212 3032 87 0 1162870212 34 00 3067 TIAI 2JZ36 87 0 1164870212 29 50 3565 23 00 X The RB25DE T NEO straight 6 engines compression ratio rises when using the RB26 or RB25 pistons due to the nature of the combustion chamber design being small Only use our specify application piston for RB25DE T NEO straight 6 30 50
16. race engine history to suit each specific engines characteristic for maximum durability The conflict of performance interest in both strength and light weight design has been taken into consideration to optimize the best overall balance A A
17. the Cylinder Gauge to verify that the clearance is within the required values N Approx 10mm below the deck surface On approx 10mm the lower side Figure is the Cylinder Block viewed from the bottom You ll find unwanted course edges at the bottom of the cylinder bore after boring Remove all metal shavings and rough edges and then chamfer approx R0 3 with a file or similar tool Do this at the bottom of the bore and all surrounding areas i 2 DEBURRING CASTING ERRORS amp RADIUS FINISH Chamfer and radius the edges and galleries to remove all casting flashes errors You can also use 400 grit sandpaper for certain areas like the bottom of the piston skirts and on sharp edges i a 3 PISTON RING ADJUSTMENTS amp PREPARATIONS Insert the Piston Ring amp position it in the middle of the oy cylinder bore by using the head of the Piston or a ring squaring tool Then check the ring gap clearances with a thickness gauge AU If the Ring Gap is too narrow and not within the required clearance values you ll have to file the edges of the Piston Rings to enlarge the gap until the gap is within the required specifications IN Thickness Gauge Adjust the Ring Gap to meet the specified clearance If the Ring Gap Clearance is not within the specified ring gap clearance values can cause possible damages amp engine failure 4 PISTON amp CONROD INSTALLATION N CAUTION E Check
18. the Piston Pin hole metal flash errors around the edges Deburr any that is found These can cause problems if they are not checked and addressed before assembly which can lead to engine failure H If you find problems with either the Piston amp or Piston Pin then do not use them 1 PISTON PIN INSPECTION Check the Piston and Piston Pin edges for metal J flash errors If found then use a 400 grit sandpaper or file to radius the edges 9 a 2 PISTON PIN ASSEMBLY Heat the connecting rods small end about 60 70 C 140 158 F to install the Piston Spread engine oil or engine assembly paste over the Piston Pin before assembly Verify that the Piston amp Connecting Rod are assembled well and that there is some free play in the neck with some movements With the 4G63 engine modify the small end of the conrod for full floating Cannot be used with the stock rods because of the press fitting type With the EJ before assemble on engine Pre assemble with verify that the piston amp connecting rod are assembled well and that there is some free play in the neck with some movement 3 CIRCLIP INSTALLATION For application except EJ CAUTION E Do not use the long nose pliers when working The Circlip will deform when a long nose pliers is used Tension is lost and the piston pin will not be secured E Because of tension loss the clip on the outer diameter will become smaller
19. figure Oil Ring below the Top Ring amp Oil Ring Side Rail Expander a itn Oil Ring is above the Side Rail Second Ring lt For application for EJ25 26 gt 1 PISTON MARK POSITIONING Pay attention to the position of the Piston Marking prior to assembly TOMEI EJ25 26 Piston notes If the Pistons are installed facing the wrong way the performance will not be the same and you ll risk possible damage to the pistons and the engine Piston mark facing the front side Piston mark facing the rear 2 PISTON RING CONFIRMATION Note the positioning of the Piston Rings when installing the Tomei Piston Kit Piston Ring Upper amp Lower Side Top Ring A Install the ring with the ring mark facing up Ring Mark Oil Ring Side Rail Gap Piston Mark A The Oil Ring Side Rail Stopper must be positioned against the raised stopper part of the Piston as shown on the left Jp Lower Side Rail Stopper Upper Side Rail Stopper or Oil Ring Stopper 20 Piston Gap Piston Mark Secondary Ring amp Oil Ring Oil Ring upper side rail 21 6 PISTON amp CONNECTING ROD ASSEMBLY INSTALLATION Z CAUTION If you didn t position the Crankshaft at Bottom Dead Center when inserting the Piston amp Conrod assembly the Crankpin amp or the Conrod bearing can be damage from the Conrod Bolt Spread engine oil or Assembly paste on the cylinder wall P
20. istons sides and the surface of the Conrod Bearing Check the Piston Rings Ring Gap position Check the Pistons front side before installing the Piston amp Connecting Rod Assembly with a Piston Ring Compressor Insert slowly and carefully to prevent any damages to the Piston Rings and the Crankpin Be sure to use the correct Conrod and Conrod Cap combination before assembling the Conrod Cap to the Conrod Tighten the Conrod Bolt with the correct torque specs as specified by the Conrods manufacturer A Never angle tighten by eye always use the correct precision tools 22 7 ASSEMBLY VERIFICATION Check the clearance of the piston in relation to the position oil jet during rotation Check that neither the Crank weight nor Piston Skirt has any interference Confirm that the Piston does not protrude more than required from the cylinder bore at Top Dead Center Be sure to calculate the final compression ratio once done 1 Cylinder Displacement cc Combustion Chamber Volume cc Gasket Capacity cc Crown Capacity cc Compression Vi Ratio V V V4 8 REPAIR PARTS amp SERVICING The Pistons specification may change at anytime without prior notification Please confirm compatibility when ordering replacement parts when you require to service rebuild or repair the engine after long term use 23 TOME POWERED wc Mest Bit 194 0004
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