Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No.1 piston is at TDC (Top dead center).
Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly”)
Remove the transaxle assembly from the engine assembly.
(Refer to Manual Transaxle System - "Manual Transaxle")
Remove the flywheel.
(Refer to Cylinder Block - "Flywheel")
Install the engine to engine stand for disassembly.
Remove the timing chain.
(Refer to Timing System - "Timing Chain”)
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhayst Manifold")
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
Remove the water pipe.
(Refer to Cooling System - "Thermostat")
Remove the water temperature control assembly.
(Refer to Cooling System - "Thermostat")
Remove the oil pan and oil screen.
(Refer to Lubrication System - "Oil Pan")
Remove the ladder frame.
(Refer to Cylinder Block - "Cylinder Block")
Check the connecting rod end play.
Remove the connecting rod caps and check oil clearance.
Check the connecting rod cap oil clearance.
Remove the piston and connecting rod assemblies.
Using a ridge reamer, remove all the carbon from the top of the cylinder.
Remove the connecting rod cap (A).
Push the piston, connecting rod assembly (B) and upper bearing through the top of the cylinder block.
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the correct order.
Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a set.
Remove the piston rings.
Using a piston ring expander, remove the 2 compression rings.
Remove 2 side rails and the spacer by hand.
Arrange the piston rings in the correct order only.
Remove the connecting rod from the piston.
Using a press, remove the piston pin from the piston.
Press-in load : 150 ~ 750 kg (331 ~ 1653 lb)
