Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
1) Relieve fuel pressure referring to Fuel Pressure Relief Procedure:M13A .
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant.
5) Remove cylinder head referring to Valves and Cylinder Head Removal and Installation:M13A .
6) Mark cylinder number on all pistons, connecting rods and connecting rod caps using silver pencil or quick drying paint.
7) Remove rod bearing caps.
8) Install guide hose (1) over threads of rod bolts.
This prevents damage to bearing journal and rod bolt threads when removing connecting rod.
9) Decarbon top of cylinder bore before removing piston from cylinder.
10) Push piston and connecting rod assembly out through the top of cylinder bore.
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins.
Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt from damage during installation of connecting rod and piston assembly.
3) When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head to crankshaft pulley side.
A: Crankshaft pulley side B: Flywheel side
4) 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
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying engine oil to rod bolts and tighten cap nuts (3) gradually as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kgf-m, 11.0 lbf-ft).
b) Retighten them to 45°
c) Repeat Step b) once again.
Before installing bearing cap, make sure to check connecting rod bolt diameter. Refer to Piston Pins and Connecting Rods Inspection:M13A .
Tightening torque
Connecting rod bearing cap nut ( a ): 15 N·m (1.5 kgf-m, 11.0 lbf-ft) and extra tightening 45° twice
6) Reverse removal procedure for installation as previously outlined.
7) Adjust generator belt tension referring to Water Pump Belt Tension Inspection and Adjustment:M13A .
8) Adjust A/C compressor and/or P/S pump belt tension (if equipped) referring Compressor Drive Belt Inspection and Adjustment (M13A Model) or P/S Pump Drive Belt Inspection and Adjustment .
9) Adjust accelerator cable play referring to Accelerator Cable Adjustment:M13A .
10) Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
11) Refill cooling system with coolant engine with engine oil and A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leakage, A/T fluid leakage (vehicle with A/T) and exhaust gas leakage at each connection.