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 (A) into the one side of piston pin holes.

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

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

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NOTE:

Before assembling the piston pin, apply a sufficient amount of engine 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.
Set the snap ring so that its cutting section is positioned at the 45° range of upper direction.

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Install the piston ring.
1. Install the oil ring expander and 2 side rails with hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Install the piston rings to ensure the ring ends are positioned as shown in below illustration.
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Install the connecting rod bearing.
1. Align the connecting rod/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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Install the bearing (B) to the connecting rod and bearing cap (A).

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:

Insert the piston while pressing down the piston ring compressor to prevent the piston ring expansion before piston ring is inserted into the cylinder.

Install the connecting rod caps (A) and then tighten the bolts to the specified torque.

Tightening torque:

17.7 - 21.6 N.m + 88 - 92° (1.8 - 2.2 kgf.m + 88 - 92°, 13.0 - 15.9 lb-ft + 88 - 92°)

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NOTE:

Always use the new connecting rod bearing cap bolt.

Install in the reverse order of removal.