Remove the oil strainer (A) and the baffle plate (B).
5.
Metal or Hard Carbon - Remove
If you can feel a ridge of metal or hard carbon around the top of any 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's pushed out.
6.
Piston/Connecting Rod Assembly - Remove
1.
Remove the connecting rod caps after setting the connecting rod journal at bottom dead center (BDC) for each cylinder. Remove the piston/connecting rod assembly by pushing on the connecting rod. Take care not to damage the oil jets, the connecting rod journal, or the cylinder with the connecting rod.
2.
Remove the bearing from the rod cap. Keep all caps/bearings in order.
3.
Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
4.
After removing a piston/connecting rod assembly, reinstall the rod cap on the rod.
NOTE:
Mark the cylinder number on the connecting rod and the connecting rod bearing cap to avoid mixing them up during reassembly.
The factory markings on the connecting rods do not indicate cylinder position.
7.
Piston Ring - Remove
1.
Using a ring expander (A), remove the old piston rings (B).
2.
Clean all the ring grooves thoroughly with a squared-off broken ring, or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top ring and second ring grooves are 1.2 mm (0.047 in) wide, and the oil ring groove is 2.8 mm (0.110 in) wide. Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tool.
NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.
8.
Piston Ring End Gap - Inspect
1.
Using a piston, push a new ring (A) into the cylinder bore 15?20 mm (0.59?0.79 in) from the bottom.
2.
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.
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.
Separately heat each piston and connecting rod assembly to about 158 °F (70 °C), then remove the piston pin.
10.
Piston Pin - Inspect
1.
Measure the diameter of the piston pin.
Piston Pin Diameter
Standard (New):
21.962?21.965 mm (0.86464?0.86476 in)
Service Limit:
21.954 mm (0.86433 in)
2.
Zero the gauge (A) to the piston pin diameter.
3.
Check the difference between the piston pin diameter and the piston pin hole diameter on the piston.
Piston Pin-to-Piston Clearance
Standard (New):
-0.0050?0.0010 mm (-0.000197?0.000039 in)
Service Limit:
0.004 mm (0.00016 in)
4.
Measure the piston pin-to-connecting rod clearance.
Piston Pin-to-Connecting Rod Clearance
Standard (New):
0.005?0.014 mm (0.00020?0.00055 in)
Service Limit:
0.019 mm (0.00075 in)
1.
Piston Pin - Install
1.
Install a piston pin snap ring (A) only on one side.
2.
Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil.
3.
Heat the piston to about 158 °F (70 °C).
4.
Assemble the piston (A) and the connecting rod (B) with the embossed marks (C) on the same side. Install the piston pin (D).
NOTE: Apply new engine oil to the piston pin.
5.
Install the remaining snap ring.
6.
Reassemble the other pistons the same way.
2.
Piston Ring - Install
1.
Install the rings as shown. The top ring (A) has a 1D or 1R mark and the second ring (B) has a 2R or SPR mark. The manufacturing marks (C) must be facing upward.
2.
After installing a new set of rings, measure the ring-to-groove clearance.
Top Ring Clearance
Standard (New):
0.055?0.080 mm (0.003?0.003 in)
Service Limit:
0.15 mm (0.005 in)
Second Ring Clearance
Standard (New):
0.030?0.055 mm (0.002?0.002 in)
Service Limit:
0.13 mm (0.005 in)
3.
Rotate the rings in their grooves to make sure they do not bind.
Position the piston/connecting rod assembly with the arrow (A) facing the timing belt side of the engine block.
2.
Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
3.
Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
5.
Connecting Rod Bolt - Inspect
1.
Measure the diameter of each connecting rod bolt at point A and point B.
2.
Calculate the difference in diameter between point A and point B.
Point A?Point B = Difference in Diameter
Difference in Diameter
Specification:
0?0.1 mm (0?0.004 in)
3.
If the difference in diameter is out of tolerance, replace the connecting rod bolt.
6.
Connecting Rod Cap and Bearing Half - Install
1.
Install the connecting rod bearing (A), then line up the mark (B) on the connecting rod (C) and the rod cap (D).
2.
Apply new engine oil to the bolt threads and flanges. Torque the bolts (E) to 20 N·m (2.0 kgf·m, 15 lbf·ft).
3.
Tighten the connecting rod bolt an additional 90 °.
NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and inspect the connecting rod bolt. Do not loosen it back to the specified angle.
