Piston, Connecting Rod, and Bearing Replacement

Removal Procedure





1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
5. Remove the oil drain plug, and drain the engine oil into a drain pan.





6. Remove the front exhaust pipe. Refer to Front Pipe Replacement (W/TWC) in Exhaust System.
7. Remove the following components from the vehicle:
^ Sixteen bolts
^ Two nuts
^ The Crankshaft Sensor (6)
^ The engine oil pan (1)
8. Remove the following components from the cylinder block:
^ The bracket bolt to the oil pump strainer
^ The oil pump strainer bolt
^ The oil pump strainer (2)





9. Remove the oil pump strainer seal (3)
10. Lower the vehicle. Remove the timing belt. Refer to Timing Belt Replacement.
11. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Replacement.
12. Remove the exhaust manifold from the cylinder head. Refer to Exhaust Manifold Replacement.
13. Remove the cylinder head from the block. Refer to Cylinder Head Replacement.
14. Mark the cylinder number on all of the pistons, on all of the connecting rods, and on all of the bearing caps.

Important: Disassemble ail of the parts by cylinder. When you reassemble the parts, return all of the parts to the correct cylinder.





15. Remove the rod bearing caps.

Notice: Install a piece of hose over the threads of the rod bolts. This is to prevent damage to the bearing journal, the cylinder walls or the rod bolt threads when removing the connecting rod. Remove hose after removal of connecting rod.

16. Install a piece of hose over the threads of the rod bolts (1).

Important: Before attempting to remove the piston from the cylinder, decarbon the top of the cylinder bore.

17. Remove the piston and the connecting rod assembly out through the top of the cylinder bore.

Installation Procedure

^ Tools Required
- J 8037 Ring Compressor

Notice: Install a piece of hose over the threads of the rod bolts. This is to prevent damage to the bearing journal, the cylinder walls, or the rod bolt threads when removing the connecting rod. Remove the hose after the connecting rod is in place.





1. Apply engine oil to the following components:
^ The pistons
^ The rings
^ The cylinder walls
^ The connecting rod bearings
^ The crankshaft





2. When installing piston assembly into the cylinder bore, point the arrow mark on the piston head to the crankshaft timing pulley side (1).





3. Install the upper connecting rod bearing to the connecting rod.
4. Install the piston assembly into the cylinder bore.
5. Guide the connecting rod into place on the crankshaft.
6. Install a J 8037, so that the tool sits firmly against the cylinder block until all of the piston rings have entered the cylinder bore.
7. Tap gently with a hammer handle on the piston head in order to install the piston into the cylinder bore.





8. Install the lower connecting rod bearing to the connecting rod cap.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the connecting rod cap (1) to the connecting rod, and secure the cap with two connecting rod cap nuts.
Tighten the connecting rod cap nuts to 35 Nm (26 ft. lbs.).





10. Install a new cylinder head gasket (2) with the TOP mark facing towards the cylinder head.
11. Install the cylinder head. Refer to Cylinder Head Replacement.
12. Install the timing belt. Refer to Timing Belt Replacement.
13. Install the intake manifold. Refer to Intake Manifold Replacement.
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
15. Install the oil pump strainer and the engine oil pan. Refer to Oil Pan Replacement.





16. Install the gasket for the engine oil drain plug and for the drain plug.
Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.).
17. Connect the negative battery cable.
18. Refill the engine oil to specifications. Refer to Capacities - Approximate Fluid.
19. Start the engine. Inspect the exhaust system for exhaust leaks.
20. Run the engine in order to inspect the engine oil pressure.