Connecting Rod: Service and Repair

Piston, Connecting Rod, and Bearing Replacement

Removal Procedure




1. Remove the engine assembly. Refer to Engine Replacement (Removal and Replacement).
2. Install the engine assembly to the stand.
3. Remove the ignition coil. Refer to Ignition Coil Replacement (Service and Repair).




4. Detach the PCV clips from the PCV hose.
5. Remove the PCV hose from the cylinder head cover.
6. Remove the cylinder head cover bolts.
7. Remove the cylinder head cover (1).
8. Remove the power steering pump and bracket. Refer to Power Steering Pump Replacement (1.2L LMU Engine) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L L95 and 1.5L LV8 Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines)).




9. Remove the timing belt. Refer to Timing Belt Replacement (Service and Repair).
10. Remove the timing belt tensioner. Refer to Timing Belt Replacement (Service and Repair).
11. Remove the camshaft intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement (Camshaft Intake Sprocket with Actuator Replacement) and Camshaft Exhaust Sprocket with Actuator Replacement (Camshaft Exhaust Sprocket with Actuator Replacement).




12. Remove the camshaft rear cover (1).




13. Remove the exhaust manifold. Refer to Catalytic Converter Replacement (1.4L LDT/1.6L LXV) (Service and Repair)Catalytic Converter Replacement (1.2L) (Service and Repair).
14. Remove the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement).
15. Remove the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).




16. Remove the engine coolant distributor (1).




17. Remove the cylinder head bolts (1).
18. Remove the cylinder head assembly (2) with the cylinder head gasket.
19. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement (Service and Repair).
20. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (Service and Repair).
21. Remove the alternator. Refer to Generator Replacement (1.4L) (Service and Repair)Generator Replacement (1.2L) (Service and Repair)Generator Replacement (1.4L LDT, 1.6L LXV) (Service and Repair).
22. Remove the starter. Refer to Starter Replacement (1.4L) (Service and Repair)Starter Replacement (1.2L DOHC) (Service and Repair)Starter Replacement (1.4L LDT, 1.6 LXV) (Service and Repair).
23. Remove the oil pan. Refer to Oil Pan Replacement (Service and Repair).
24. Remove the oil pump assembly. Refer to Oil Pump Replacement (Service and Repair).
25. Remove the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement (Service and Repair) and Engine Flywheel Replacement (Service and Repair).





Note: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.

26. Remove the connecting rod cap (2) and bolts (3).
27. Remove the piston assembly (1).




28. Separate the piston pin (5) from the piston.
29. Separate the piston ring (1) from the piston (3) using the expansion tool.

Installation Procedure





Note: Take extreme care to prevent any scratches or damage to the inner side of the cylinder, piston, and connecting rod cap bearings.

1. Install the piston pin (5) to the piston.
2. Install the piston ring (1) from the piston (3) using the expansion tool.

Note: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.

3. Install the piston assembly using the piston installer (1.6L only - EN-49153).

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the connecting rod cap and bolts with bearings.

Tighten the connecting rod caps bolts to 35+45° +15° Nm (25.8+45° +15° lb ft).

5. Install the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement (Service and Repair) and Engine Flywheel Replacement (Service and Repair).
6. Install the oil pump assembly. Refer to Oil Pump Replacement (Service and Repair).
7. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement (Service and Repair).
8. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (Service and Repair).
9. Install the alternator. Refer to Generator Replacement (1.4L) (Service and Repair)Generator Replacement (1.2L) (Service and Repair)Generator Replacement (1.4L LDT, 1.6L LXV) (Service and Repair).
10. Install the starter. Refer to Starter Replacement (1.4L) (Service and Repair)Starter Replacement (1.2L DOHC) (Service and Repair)Starter Replacement (1.4L LDT, 1.6 LXV) (Service and Repair).
11. Install the oil pan. Refer to Oil Pan Replacement (Service and Repair).





Note: Do not reuse the cylinder head gasket.

12. Install the cylinder head assembly (2) with the new cylinder head gasket.
13. Install the cylinder head bolts (1).

Tighten the cylinder head bolts to 25+90° +90° +90° +45° Nm (18.4+90° +90° +90° +45° lb ft).




14. Install the engine coolant distributor (1).
15. Install the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).
16. Install the throttle body. Refer to Throttle Body Assembly Replacement (Removal and Replacement)..
17. Install the exhaust manifold. Refer to Catalytic Converter Replacement (1.4L LDT/1.6L LXV) (Service and Repair)Catalytic Converter Replacement (1.2L) (Service and Repair).




18. Install the camshaft rear cover (1).
19. Install the camshaft intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement (Camshaft Intake Sprocket with Actuator Replacement) and Camshaft Exhaust Sprocket with Actuator Replacement (Camshaft Exhaust Sprocket with Actuator Replacement).
20. Install timing belt system and adjust the timing. Refer to Timing Belt Replacement (Service and Repair).
21. Install the accessory belt. Refer to Drive Belt Replacement (Drive Belt Replacement).
22. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement (1.2L LMU Engine) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L L95 and 1.5L LV8 Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines)).




23. Install the cylinder head cover (1).
24. Install the cylinder head cover bolts.
25. Install the PCV hose from the cylinder head cover.
26. Attach the PCV clips from the PCV hose.
27. Install the ignition coil. Refer to Ignition Coil Replacement (Service and Repair).