1D
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
Reference: Pistons, Piston Rings, Connecting Rods and Cylinders Components:K9K
CAUTION:
Connecting rod and connecting rod bearing must be replaced as a set when either replacement becomes necessary.
Removal
1) Remove engine assembly from vehicle referring to Engine Assembly Removal and Installation:K9K .
2) Remove cylinder head referring to Valves and Cylinder Head Assembly Removal and Installation:K9K .
3) Remove upper oil pan referring to Oil Pan and Oil Pump Strainer Removal and Installation:K9K .
4) Remove oil pump referring to Oil Pump and Oil Pump Chain Removal and Installation:K9K .
5) Remove special tool (A).
Special Tool
(A) : 09919–58110
6) Mark cylinder number on all pistons, connecting rods (1) and rod bearing caps (2) using silver pencil or quick drying paint (3) for installation.
7) Remove connecting rod bearing caps.
8) Decarbon top of cylinder bore before removing piston from cylinder.
9) Push piston and connecting rod assembly out through the top of cylinder bore.
Installation
Reference: Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly:K9K
NOTE:
• All parts to be installed must be perfectly clean.
• Main bearings, main bearing caps, connecting rods, connecting rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.
1) Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins.
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 arrow mark (1) on piston head to flywheel side (2).
3) Install piston and connecting rod assembly into cylinder bore matching cylinder number marked in removal. 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 bearing cap (1) to applicable cylinder matching cylinder number marked in removal.
a) Tighten all cap bolts (2) to 20 N·m (2.0 kgf-m, 14.5 lbf-ft).
b) Retighten them by turning through 45°.
Tightening torque
Connecting rod bearing cap bolt ( a ): Tighten 20 N·m (2.0 kgf-m, 14.5 lbf-ft) and 45° by the specified procedure
5) Insert special tool into TDC pin hole as shown in the figure.
And turn crankshaft clockwise until crankshaft touches special tool.
Special Tool
(A) : 09919–58110
6) Install oil pump referring to Oil Pump and Oil Pump Chain Removal and Installation:K9K .
7) Install oil pan and oil level gauge referring to Oil Pan and Oil Pump Strainer Removal and Installation:K9K .
8) Install cylinder head referring to Valves and Cylinder Head Assembly Removal and Installation:K9K .
9) Install engine assembly to vehicle referring to Engine Assembly Removal and Installation:K9K .