Removal

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

Removal

1. Intake Manifold and Throttle Body Assembly

1. Remove the intake air duct.

2. Remove the heater hose clamp bracket.

3. Disconnect the water bypass hoses (A).

4. Disconnect the PCV hose (B).

5. Disconnect the connectors (C).

6. Remove the harness clamps (D).

7. Remove the intake manifold bracket.

8. Remove the intake manifold and throttle body assembly from the cylinder head.

2. Engine Wire Harness

1. Remove the engine wire harness.

3. Manual Transmission Assembly (M/T)

1. Remove the manual transmission.

4. Pressure Plate

1. Install the ring gear holder.

2. Install the clutch alignment shaft and the remover handle.

3. To prevent warping, loosen the pressure plate mounting bolts (A) in a crisscross pattern in several steps.

4. Remove the pressure plate (B).

5. Clutch Disc

1. Remove the clutch disc (A), the clutch alignment shaft, and the remover handle.

6. Flywheel

1. Remove the flywheel (A).

NOTE: Loosen the flywheel mounting bolts (B) in a crisscross pattern in several steps.

2. Remove the ring gear holder.

7. Automatic Transmission Assembly (A/T)

1. Remove the automatic transmission.

8. Drive Plate Assembly

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

9. A/F Sensor (Sensor 1)

1. Disconnect the connector.

2. Remove the A/F sensor (A).

10. Exhaust Chamber Cover

1. Remove the exhaust chamber cover (A).

11. Catalytic Converter and EGR Pipe Assembly

1. Remove the EGR pipe.

2. Remove the catalytic converter.

12. Thermostat Housing

1. Remove the thermostat housing.

13. Alternator

1. Remove the alternator.

14. Lower Torque Rod Bracket (M/T)

1. Remove the lower torque rod bracket.

15. Lower Torque Rod Bracket (A/T)

1. Remove the lower torque rod bracket.

16. Intermediate Shaft Assembly

1. Remove the crankshaft position (CKP) sensor cover (A).

2. Remove the intermediate shaft (A) from the differential.

NOTE: Hold the intermediate shaft horizontal until it is clear of the differential to prevent damaging the oil seal (B).

17. A/C Compressor Bracket

1. Remove the A/C compressor bracket.

18. Water Pump Pulley

1. Remove the water pump pulley.

19. Auto Tensioner Assembly

1. Remove the drive belt auto-tensioner (A).

2. Check for oil leaks from the drive belt auto-tensioner damper (B) and check for damage to the damper rubber.

20. Cylinder Head Cover and/or Packing

1. Remove the dipstick (A).

2. Disconnect the breather hose (B).

3. Remove the cylinder head cover.

21. Check 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 "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

22. 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.

3. Remove the crankshaft pulley.

23. Engine Oil Pump Assembly

1. Disconnect the PCV hose.

2. Remove the oil pump.

24. Cam Chain Auto-Tensioner

1. Measure the tensioner rod length between the tensioner body and bottom of the flat surface section on the tensioner rod. If the length is more than the service limit, replace the cam chain.

2. Loosely install the crankshaft pulley.

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

4. Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the auto-tensioner (B).

5. Insert a 1.0 mm (1/32 in) diameter pin (C) into the holes.

6. 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.

7. Remove the cam chain auto-tensioner.

8. Remove the crankshaft pulley.

25. Cam Chain

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

2. Remove the cam chain.

26. 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.

27. Oil Pan Assembly

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

2. Remove the oil pan.

28. Engine Oil Strainer

1. Remove the oil strainer.

29. Engine Baffle Plate

1. Remove the baffle plate.

30. Connecting Rod Cap and The Bearing Half

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

31. Cylinder Lower Block Assembly

1. Remove the 8 mm bolts in the sequence shown.

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

3. Using a flat blade screwdriver, separate the lower block from the engine block in the places shown.

4. Remove the lower block and the bearings. Keep all the bearings in order.

32. Crankshaft

1. Lift the crankshaft (A) out of the engine block.

2. Remove the thrust washers (B).

33. Crankshaft Oil Seal, Transmission Side

1. Remove the transmission end crankshaft oil seal.

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 (A). 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). Take care not to damage the oil jets or cylinder with the connecting rod.

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 Ring

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 2.0 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 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.

36. 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 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 connecting rod assembly to about 158 °F (70 °C).

4. Remove the piston pin.

Inspection

1. Piston, Pin, and Connecting Rod and Piston Pin Hole 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.