Piston: Service and Repair
Removal Procedure1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
2. Disconnect the negative battery cable.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
5. Remove the oil drain plug and drain the engine oil into a drain pan.
6. Remove the front exhaust pipe. Refer to Front Pipe Replacement (TWC) in Exhaust System.
7. Remove the following components from the vehicle:
^ Sixteen bolts
^ Two nuts
^ Crankshaft Sensor (6)
^ The engine oil pan (1)
8. Remove the following components from the cylinder block:
^ The oil pump strainer bracket bolt
^ The oil pump strainer bolt
^ The oil pump strainer (2)
^ Remove the oil pump strainer seal (3)
9. Lower the vehicle.
10. Remove the timing belt.
11. Remove the intake manifold from the cylinder head.
12. Remove the exhaust manifold from the cylinder head.
13. Remove the cylinder head from the block.
14. Mark the cylinder number on all of the pistons, connecting rod and the bearing caps.
IMPORTANT: When disassembling, keep all of the parts in order by cylinder and return them to the correct cylinder.
15. Remove the rod bearing caps.
NOTICE: Install a piece of hose over the threads of the rod bolts. This is to prevent damage to the bearing journal, the cylinder walls or the rod bolt threads when removing the connecting rod. Remove hose after removal of connecting rod.
16. Install a piece of hose over the threads of the rod bolts (1).
IMPORTANT: Decarbon the top of the cylinder bore before attempting to remove the piston from the cylinder.
17. Remove the piston and the connecting rod assembly out through the top of the cylinder bore.
Installation Procedure
Tools Required
^ J 8037 Ring Compressor
NOTICE: Install a piece of hose over the threads of the rod bolts. This is to prevent damage to the bearing journal, the cylinder walls, or the rod bolt threads when removing the connecting rod. Remove the hose after the connecting rod is in place.
1. Apply engine oil to the following components:
^ The pistons
^ The rings
^ The cylinder walls
^ The connecting rod bearings
^ The crankshaft
2. When installing piston assembly into the cylinder bore, point the arrow mark on the piston head to the crankshaft timing pulley side.
3. Install the upper connecting rod bearing to the connecting rod.
4. Install the piston assembly into the cylinder bore.
5. Guide the connecting rod into place on the crankshaft.
6. Install a J 8037 ensuring it sits firmly against the cylinder block until all of the piston rings have entered the cylinder bore.
7. Tap gently with a hammer handle on the piston head to install the piston into the cylinder bore.
8. Install the lower connecting rod bearing to the connecting rod cap.
NOTICE: Refer to Fastener Notice in Service Precautions.
9. Install the connecting rod cap to the connecting rod and secure with two connecting rod cap nuts.
Tighten the connecting rod cap nuts to 35 Nm (26 ft. lbs.)
10. Install a new cylinder head gasket (2) with the TOP mark facing up (towards the cylinder head).
11. Install the cylinder head.
12. Install the timing belt.
13. Install the intake manifold.
14. Install the exhaust manifold.
15. Install the oil pump strainer and the engine oil pan.
16. Install the engine oil drain plug gasket and the drain plug.
Tighten the engine oil drain plug to 35 Nm (26 ft. lbs.)
17. Connect the negative battery cable.
18. Refill the engine oil to specifications.
19. Start the engine. Inspect the exhaust system for exhaust leaks.
20. Run the engine in order to inspect the engine oil pressure.