1.
Assemble the piston and connecting rod.
(1)
Use a hydraulic press for installation.
(2)
The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
Assemble the piston and connecting rod.
Use a hydraulic press for installation.
The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
Install the piston rings.
Install the oil ring expender and 2 side rails by hand.
Using a piston ring expender, install the 2 compression rings with the code mark facing upward.
Position the piston rings so that the ring ends are as shown.
Install the connecting rod bearings.
Align the bearing claw with the groove of the connecting rod and connecting rod cap.
Install the bearings (A) in the connecting rod and connecting rod cap (B).
Install the piston and connecting rod assemblies.
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the engine.
Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
Stop after the ring compressor pops free, and check the connecting rod to check journal alignment before pushing the piston into place.
Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.
Always use new connecting rod bearing cap bolts.
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
Tightening torque :
11 ~ 15 N.m (1.1 ~ 1.5 kgf.m, 8.0 ~ 10.8 lb-ft) + 88 ~ 92°
Using the SST (09221-4A000), tighten the bolts which need to be tightened with the angular tightening method.
Always use new connecting rod cap bolts. Connecting rod cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
Check the connecting rod end play.
Assemble the other parts in the reverse order of disassembly.
