Piston, Piston Ring and Connecting Rod Removal and Installation

Piston, Piston Ring and Connecting Rod Removal and Installation

CAUTION:
Keep the following parts in order. They must go back in the position from which they were removed.
^ Connecting rod
^ Connecting rod bearing
^ Connecting rod bearing cap
^ Piston

Removal
1) Remove engine assembly from vehicle.
2) Remove cylinder head.
3) Remove oil pump.
4) Mark cylinder number on all pistons, connecting rods and connecting rod bearing caps using silver pencil or quick drying paint.
5) Remove connecting rod bearing caps.
6) Remove carbon deposits from tops of cylinder bores before removing pistons from cylinder.
7) Push piston and connecting rod assembly out through the top of cylinder bore.
8) Remove connecting rod bearings from connecting rod and connecting rod bearing cap, if necessary.

Installation

CAUTION:
^ Apply engine oil to the following parts.
^ Crankshaft pin
^ Connecting rod bearing
^ Piston
^ Piston ring
^ Cylinder wall
^ Install the following parts in the position from which they were removed.
^ Connecting rod
^ Connecting rod bearing
^ Connecting rod bearing cap
^ Piston

1) Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft pins.

NOTE:
Do not apply engine oil between connecting rod and bearing, between connecting rod bearing cap and bearing.

2) Install connecting rod bearing to connecting rod bearing cap and connecting rod as follows.
a) Fit tab (1) of connecting rod bearing to groove (2) of connecting rod or bearing cap.
b) Press bearing end (3) until it fully seats in connecting rod and bearing cap.





3) When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head to crankshaft pulley side (2).








4) Install piston and connecting rod assembly into cylinder bore. Use special tool to compress rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered in cylinder bore.
Special Tool
(A): 09916-77310





5) Install connecting rod bearing cap (1) as follows.

NOTE:
^ Before installing connecting rod bearing cap, check connecting rod bearing cap bolts for deformation.
^ Tighten connecting rod bearing cap bolt (3) gradually.

a) Point arrow mark (2) on connecting rod bearing cap (1) to crankshaft pulley side.
b) Apply engine oil to bolt thread and seat of connecting rod bearing cap bolt.
c) Tighten all connecting rod bearing cap bolt to 15 Nm (1.5 kgf-m, 11.0 lbf-ft) evenly and gradually.
d) In the same manner as Step c), retighten them to 45 degrees.
e) In the same manner as Step c), retighten them to 45 degrees.
Tightening torque
Connecting rod bolt* (a): 15 Nm -> +45 degrees -> +45 degrees (1.5 kgf-m -> +45 degrees -> +45 degrees, 11.0 lbf-ft -> +45 degrees -> +45 degrees





6) Install oil pump.
7) Install cylinder head.
8) Install engine assembly.