Removal

Piston, Ring, Pin, and Connecting Rod Removal and Installation

















Removal

1. Starter





1. Remove the starter bolts.





2. Disconnect the cable and the connector.

3. Remove the starter.

2. Alternator





1. Remove the three bolts securing the alternator.





2. Disconnect the connector and the cable.

3. Remove the alternator.

3. Ignition Coil Cover





1. Remove the ignition coil cover.

4. Engine Wire Harness





1. Remove the engine wire harness.

5. A/T Intermediate Shaft Assembly





1. Remove the flange bolt (A) and the two dowel bolts (B).





2. Remove the intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal (B).

6. Automatic Transmission Assembly (After Removal Engine)





1. Remove the torque converter cover (A).

2. Remove the torque converter bolts (B) (8 bolts) while rotating the crankshaft pulley.





3. Remove the automatic transmission.

7. Drive Plate Assembly





1. Remove the drive plate (A) and the washer (B).

8. Intake Manifold and Throttle Body Assembly





1. Remove the intake manifold lower bracket.





2. Remove the intake manifold with the throttle body.

9. Fuel Injector and Rail Assembly





1. Remove the rail with the fuel injector.

10. Injector Base Assembly





1. Remove the injector base (A).

11. Water Passage Assembly





1. Remove the water passage.

12. A/F Sensor





1. Remove the A/F sensor.

13. Warm Up TWC





1. Remove the exhaust chamber cover (A).

2. Remove the warm up TWC (B).

14. Ignition Coil





1. Remove the ignition coils.

15. Cylinder Head Cover





1. Remove the dipstick (A).

2. Disconnect the breather hose (B).

3. Remove the two bolts (C).





4. Remove the cylinder head cover.

16. Set The Crankshaft To Top Dead Center





1. Turn the crankshaft so its white mark (A) lines up with the pointer (B).

NOTE: The other pointer (C) is not used.

17. Set The No.1 Piston at Top Dead Center (With Cam Chain Case/Oil Pump)





1. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

18. VTC Oil Control Solenoid Valve





1. Remove the VTC oil control solenoid valve.

19. Crankshaft Pulley





1. Hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

2. Remove the bolt with a socket, 19 mm (C) and a breaker bar, then remove the crankshaft pulley.

20. Oil Pan Assembly (Without Transmission)





1. Remove the bolts securing the oil pan.

2. Using a flat blade screwdriver, separate the oil pan from the engine block in the places shown.





3. Remove the oil pan.

21. Side Engine Mount Bracket, Engine Side





1. Remove the side engine mount bracket.

22. Cam Chain Case





1. Remove the cam chain case (A) and the spacer (B).

23. Cam Chain Auto-Tensioner





1. Loosely install the crankshaft pulley.

2. Turn the crankshaft counterclockwise to compress the auto-tensioner.





3. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.

NOTE: If the holes in the lock and the auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.





4. Remove the auto-tensioner.

24. Cam Chain Tensioner Arm and Cam Chain Guide





1. Remove cam chain guide B.





2. Remove cam chain guide A and the tensioner arm (B).

25. Cam Chain

1. Remove the cam chain.

26. Camshaft Holder





1. Loosen the rocker arm and the adjusting screws (A).





2. Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.





3. Remove cam chain guide B , the camshaft holders (A).

27. Camshaft





1. Carefully tip up the intake camshaft on the transmission side of the engine until there is enough slack in the chain to lift the chain off of the VTC actuator's teeth.

2. Remove the intake camshaft and the exhaust camshaft while keeping some tension on the cam chain.

3. Secure the cam chain to the A/C compressor suction hose with a wire tie to prevent the chain from falling down into the chain case.

28. Rocker Arm Assembly





1. Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).

29. Cylinder Head Assembly





1. Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

2. Remove the cylinder head.

30. Oil Pump Chain Tensioner





1. Loosely install the crankshaft pulley.

2. To hold the rear balancer shaft, insert a 6 mm long pin punch (A) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.

3. Turn the crankshaft counterclockwise to compress the oil pump chain auto-tensioner.

4. Remove the crankshaft pulley.





5. Align the holes on the lock (A) and the oil pump chain auto-tensioner (B), then insert a 3.0 mm (7/64 in) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.





6. Use a transmission jack to lift the transmission 30-40 mm (1.18-1.57 in), then remove the oil pump chain auto-tensioner.

31. Engine Oil Pump Assembly





1. Loosen the oil pump sprocket mounting bolt.





2. Remove the oil pump sprocket (A) and the oil pump chain guide (B).

3. Remove the oil pump chain (C).





4. Remove the oil pump.

32. Engine Baffle Plate





1. Remove the baffle plate.

33. Connecting Rod Caps/Bearing Halves





1. Remove the connecting rod caps/bearing. Keep all connecting rod caps/bearing halves in order.

34. Piston/Connecting Rod Assembly





1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer. Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it is pushed out.





2. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B).

3. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.

4. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reinstalled in the original order.

NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

35. Piston Pin





1. Apply new engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B).

NOTE: Take care not to damage the ring grooves.





2. Remove the snap rings (A) from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection.





3. Heat the piston and the connecting rod assembly to about 158 °F (70 °C).

4. Remove the piston pin.

Inspection

1. Piston Ring End Gap - Inspection





1. Using a ring expander (A), remove the old piston rings (B).

2. Clean all ring grooves thoroughly with a squared-off broken ring or a ring groove cleaner with a blade to fit the piston grooves. The top and second ring grooves are 1.2 mm (0.047 in) wide. The oil ring groove is 2.0mm(0.079 in) wide. The top ring groove is 1.2 mm (0.047 in) wide. The second ring groove is 1.0 mm (0.039 in) wide. The oil ring groove is 2.0 mm (0.079 in) wide. File down a blade if necessary. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools.

NOTE: If the piston is to be separated from the connecting rod, do not install the new rings yet.

3. Using a piston that has its rings removed, push a new ring (A) into the cylinder bore 15-20 mm (0.59-0.79 in) from the bottom.






4. Measure the piston ring end-gap (B) with a feeler gauge:

* If the gap is too small, check to see if you have the proper rings for your engine.
* If the gap is too large, recheck the cylinder bore diameter against the wear limits.
* If the bore is beyond the service limit, the engine block must be rebored.








2. Piston Pin - Inspection

1. Measure the diameter of the piston pin.
















2. Zero the dial indicator to the piston pin diameter.

3. Check the difference between the piston pin diameter and the piston pin hole diameter in the piston.












4. Measure the piston pin-to-connecting rod clearance.