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Positive Crankcase Ventilation Tube Replacement > < Exhaust Gas Recirculation Valve Cooler Assemble

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Piston, Connecting Rod, and Bearing Replacement

Special Tools

•  EN-45059   Torque Angle Sensor
•  CH-49290   Mounting Engine / Transmission

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Remove the cylinder head. Refer to Cylinder Head Replacement .
3. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
4. Install the engine mount. Refer to Engine Mount Replacement .
5. Remove the CH-49290   mounting , for disassembly use attached installation manual.
6. Remove the oil pan. Refer to Oil Pan Replacement .
7. Set crankshaft to TDC of combustion stroke of cylinder 1.

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8. Remove and DISCARD the 4 connecting rod bearing cap bolts (4) from the cylinder 2 and 3.

Note:  Note the marking (2) of the connecting rod bearing caps.

Note:  The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
9. Remove the 2 connecting rod bearing caps (3) from the cylinder 2 and 3.
10. Remove the 2 connecting rod lower bearings (1).

Note:  Set aside in the order removed.
11. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Take extreme care to prevent damage to the cylinder bore surface, piston ring and piston surface.
12. Push the 2 pistons with connecting rod (1) from the cylinder 2 and 3 upwards.

Note:  Note the marking (2) of the connecting rod. Set aside in the order removed.
13. Remove the 2 connecting rod upper bearings (3) from the cylinder 2 and 3.
14. Turn the crankshaft through 180° and set the crankshaft to TDC of combustion stroke of cylinder 2.
15. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

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16. Remove and DISCARD the 4 connecting rod bearing cap bolts (4) from the cylinder 1 and 4.

Note:  Note the marking (2) of the connecting rod bearing caps. Set aside in the order removed.

Note:  The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
17. Remove the 2 connecting rod bearing caps (3) from the cylinder 1 and 4.

Note:  Set aside in the order removed.
18. Remove the 2 connecting rod lower bearings (1).
  Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Take extreme care to prevent damage to the cylinder bore surface, piston ring and piston surface.
19. Push the 2 pistons with connecting rod (1) from the cylinder 1 and 4 upwards.

Note:  Note the marking (2) of the connecting rod. Set aside in the order removed.
20. Remove the 2 connecting rod upper bearings (3) from the cylinder 1 and 4.
21. For disassemble piston and connecting rod. Refer to Piston and Connecting Rod Disassemble .

Installation Procedure

1. For assemble piston and connecting rod. Refer to Piston and Connecting Rod Assemble .

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2. Turn the piston rings before the installation to a position (A, B C) as in the graphic shown.

Note:  Arrow on piston head points to engine timing side.
3. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring with clean engine oil.
4. Install the piston ring compressor in order to compress the piston rings.

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Note:  Take extreme care to prevent damage to the cylinder bore surface, piston ring and piston surface.
5. Install the 2 connecting rod upper bearings (3) to the connecting rod of the cylinder 2 and 3.
  Push the 2 pistons with connecting rod (1) to the cylinder 1 and 4.
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Take extreme care to prevent any scratches or damages to the connecting rod bearings.
7. Install the 2 connecting lower bearings (1).
8. Install the 2 connecting rod bearing caps (3) to the cylinder 1 and 4.

Caution: Refer to Fastener Caution .
9. Install the 4 NEW connecting rod bearing cap bolts (4) to the cylinder 1 and 4 and tighten in two passes:
  •  First pass to 25 N·m (18 lb ft) .
  •  Second pass to 60° , using the EN-45059   sensor .
10. Turn the crankshaft through 180° and set crankshaft to TDC of combustion stroke of cylinder 2.
11. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Take extreme care to prevent damage to the cylinder bore surface, piston ring and piston surface.
12. Install the 2 connecting rod upper bearings (3) to the connecting rod of the cylinder 2 and 3.
13. Push the 2 pistons with connecting rod (1) to the cylinder 2 and 3.
14. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

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Note:  Take extreme care to prevent any scratches or damages to the connecting rod bearings.
15. Install the 2 connecting rod lower bearings (1).
16. Install the 2 connecting rod bearing caps (3) to the cylinder 2 and 3.
17. Install the 4 NEW connecting rod bearing cap bolts (4) to the cylinder 2 and 3 and tighten in two passes:
  •  First pass to 25 N·m (18 lb ft) .
  •  Second pass to 60° , using the EN-45059   sensor .
18. Set the crankshaft in direction of the engine rotation to 60° before TDC of combustion stroke of cylinder 1.
19. Install the oil pan. Refer to Oil Pan Replacement .
20. Install the CH-49290   mounting , for assembly use attached installation manual.
21. Remove the engine mount. Refer to Engine Mount Replacement .
22. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .
23. Install the cylinder head. Refer to Cylinder Head Replacement .
24. Close the hood.

Positive Crankcase Ventilation Tube Replacement > < Exhaust Gas Recirculation Valve Cooler Assemble