Repair Procedures: Reassembly

WARNING: This page is about a different variant/trim than selected.

NOTE:

Clean the each part before assembling.
Apply new engine oil on the sliding/rotating surface before assembling parts.
Always use the new gasket, O-ring and oil seal.

Assemble the piston and the connecting rod.

Insert the snap ring into the one side of piston pin hole.

Align the piston front mark (A) and the connecting rod front mark (B).

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Insert the piston pin into the piston pin hole and the small end bore of connecting rod.
Insert the snap ring into the another piston pin hole.

NOTE:

Before assembling the piston pin, apply a sufficient amount of engine oil to the outer surface of piston, inner surface of piston hole and connecting small end bore
When inserting, be careful not to damage or scratch the connecting rod small end hole, piston pin and piston pin hole.
Set the snap ring so that it contacts securely with the whole groove of the piston pin hole.

Install the piston ring.
1. Install the coil spring and oil ring by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown.
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Install the connecting rod bearing.
1. Align the connecting rod and bearing cap (A) grooves and the protrusion of bearing (B).
2. Install the bearing (B) to the connecting rod and bearing cap (A).
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NOTE:
- Be careful not to change the position of bearing caps.

Install the piston and connecting rod assembly.

NOTE:

Before assembling the piston, apply a small amount of engine oil on the piston ring groove and the inner surface of cylinder.
The piston front mark (A) and the connecting rod front mark (B) should face the timing chain.

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Install the piston ring compressor while checking that the piston ring is securely in place. Put the piston in the cylinder and then tap it in using the wooden handle of a hammer.

Stop once the piston ring is inserted into the cylinder and then recheck the alignment of journal and connecting rod before pushing the piston into place.

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NOTE:

Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.

Install the connecting rod bearing caps (A) with bearings, and tighten the bolts.

Tightening torque:

27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft) + 68 - 72°

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NOTE:

Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-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.

Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.

Tightening torque:

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Fig 1: Baffle Plate Bolts Tightening Sequence
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Assemble the other parts in the reverse order of disassembly.