Piston: Service and Repair

1. Remove timing belt cover, timing belt, rocker assembly, camshaft and cylinder head.
2. Remove oil filter, then the alternator, wiring harness and alternator bracket.
3. Remove engine mounting bracket and mounting stay.
4. Lock flywheel with suitable tool, then remove attaching bolts and flywheel.
5. Remove oil dipstick and dipstick tube, then the flywheel housing.
6. Remove oil pan attaching bolts and the oil pan.

Fig. 31 Exploded View Of Crankcase, Oil Pump & Water Pump:

7. Remove water pump cover and impeller, then the water pipe, Fig. 31. Use a screwdriver to prevent balancer shaft from rotating when removing impeller.
8. Remove oil pump cover attaching bolts, then the cover and inner and outer rotors.
9. Remove crankcase cover.
10. Remove connecting rod cap nuts, then tap piston/rod assemblies from underneath with hammer handle and remove assemblies from crankcase.

Fig. 32 Exploded View Of Crankshaft, Pistons, & Balance Shaft:

11. Remove balancer chain, chain guide and oil pump sprocket, Fig. 32.
12. Remove main bearing cap attaching bolts, then the caps and crankshaft.
13. Carefully remove balancer shaft from crankcase.
14. Press piston pins from connecting rod small end using suitable tool.
15. Ensure all components are clean and free from foreign material, and that oil passages are clear. Coat all friction surfaces with oil or suitable assembly lubricant.

Fig. 33 Assembling Piston To Connecting Rod:

16. Assemble piston to connecting rod so that intake valve recesses on piston and crescent mark on connecting rod are positioned as shown, Fig. 33.
17. Install rings onto pistons. Ensure R1 (top ring) and R2 (second ring) marks on compression rings face upward.
18. Install balancer shaft and oil pump sprocket, then temporarily install chain guide. If replacing chain and/or chain guide, always replace them in the following combinations:
a. If replacing chain only, replacement chain should have green color identification.
b. If replacing chain guide only, and original chain guide is white, replacement guide should have white color identification. If original chain guide is blue, replacement guide should have blue color identification. If original chain guide is green, replacement guide should have white or blue color identification.
c. If replacing chain and chain guide, and original chain guide is white or blue, replacement guide should be same as original, and replacement chain should have green color identification.
19. Install main bearing halves into crankcase.

Fig. 34 Installing Drive Chain:

Fig. 35 Piston Ring Installation:

20. Install chain and crankshaft, then align marks on sprockets with gold links on chain as shown in Fig. 34.
21. Install main bearing caps with arrows facing front of engine. Tighten bolts to specifications.
22. Position ring end gaps as shown, Fig. 35, then install piston/rod assemblies into cylinders. Ensure intake valve recesses on piston face intake manifold side of engine.
23. Install connecting rod bearing caps. Tighten nuts to specifications.
24. Install rear oil seal using suitable tools.
25. Install crankcase cover together with air suction manifold bracket.
26. Install oil pump inner rotor, outer rotor and cover. Ensure inner rotor shaft aligns with groove in sprocket.
27. Water Pump installation:
a. Coat outer circumference of new water pump seal with Three-Bond 1303 sealant or equivalent, then drive seal into crankcase cover.
b. Coat seal lip with coolant, then press pump impeller against balancer shaft and measure tip clearance. Tip clearance should be .012-.035 inch. If clearance is not as specified, add spacers as required.
c. Position screwdriver between balancer shaft weight and crankcase, then install impeller attaching bolt and tighten to specifications.
d. Install water pump cover using new gasket.
28. Install oil pan with new gasket. Tighten bolts to specifications.
29. Install flywheel housing.
30. Install oil dipstick tube and dipstick.
31. Install flywheel and attaching bolts. Lock flywheel using suitable tool and torque attaching bolts to specifications.
32. Install oil filter, engine mounting bracket and mounting stay.
33. Install alternator mounting bracket and alternator.
34. Install cylinder head, camshaft, rocker assembly, timing belt and timing belt cover as outlined previously.