Removal and Installation

Piston, Piston Ring and Connecting Rod Removal and Installation

NOTE:

If any of the parts listed below is reinstalled into a position different from the original position, engine problems could occur.

If these parts are to be reused, keep them in numerical order so that they may be reinstalled in their original positions.

- Connecting rods
- Connecting rod bearings
- Connecting rod bearing caps
- Pistons

Removal

Piston, Piston Ring and Connecting Rod Components
1) Remove engine assembly from vehicle. Removal and Replacement
2) Remove cylinder head. Removal and Replacement
3) Remove oil pump. Removal and Replacement
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

Piston, Piston Ring and Connecting Rod Disassembly and Reassembly

Crankshaft Pin and Connecting Rod Bearing Inspection

NOTE:

The engine will seize up if it is operated when the parts listed below are not properly lubricated.

Be sure to lubricate all the friction surfaces of these parts with engine oil before installing them.

- Crankshaft pins
- Connecting rod bearings
- Pistons
- Piston rings
- Cylinder walls

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

NOTE:
If oil is present between the bearing's outside surface and the connecting rod surface, the bearing could heat up to very high temperature, resulting in seizure.

Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the connecting rod surface.

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:
Using connecting rod bolts that are deformed exceeding the service limit could lead to engine problems.

Before installing connecting rod bearing cap, make sure that connecting rod bolts are not deformed exceeding the service limit referring to "Connecting rod bolt deformation" under Piston Pin and Connecting Rod Inspection Piston Pin and Connecting Rod Inspection.

NOTE:
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°.
e) In the same manner as Step c), retighten them to 45°.

Tightening torque
Connecting rod bolt* (a): (15 Nm -> +45° -> +45° (1.5 kgf-m -> +45° -> +45°, 11.0 lbf-ft -> +45° -> +45°)





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