Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation

Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation

Removal
1. Remove oil pump with oil pump strainer.
2. Remove cylinder head.
3. Mark cylinder number on all pistons, connecting rods and connecting rod caps.
4. Remove connecting rod bearing caps.
5. Clean carbon from top of cylinder bore before removing piston from cylinder.
6. Push piston and connecting rod assembly out through the top of cylinder bore.

Installation

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

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

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








3. Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) 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 cylinder bore.
Special Tool (A):09916-77310





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

NOTE: If connecting rod bolt is reused, make sure to check connecting rod bolt for deformation.

a) Point arrow mark (2) on cap to crankshaft pulley side.
b) Apply engine oil to new connecting rod bolts (3).
c) Tighten all connecting rod bolts to 15 Nm (1.5 kgf-m, 11.0 ft. lbs.).
d) Retighten them by turning through 45°.
e. Repeat step d) once again.

Tightening torque
Connecting rod bolt a: Tighten 15 Nm (1.5 kgf-m, 11.0 ft. lbs.), 45° and 45° by the specified procedure





5. Install cylinder head.
6. Install oil pan.
7. Install camshafts and tappets and shims.
8. Install 1st timing chain.
9. Install 2nd timing chain.
10. Install timing chain cover.
11. Check intake and exhaust valve lashes.
12. Install cylinder head cover.
13. Install engine assembly to vehicle.