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T3B11B23
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Oil Pump

Tools Required

KM-498-B Pressure Gauge
KM-135 Adapter

Engine Oil Pressure Inspection Procedure

  1. Remove the right-hand wheel well splash shield.
  2. Remove the oil pressure switch connector.

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  3. Install the adapter KM-135 in place of the oil pressure switch.
  4. Connect the pressure gauge KM-498-B to the adapter.
  5. Start the engine and check the oil pressure at idle speed and an engine temperature of 80°C (176°F).

    6. Important : The minimum oil pressure should be 30 kPa(8.88psi).

  6. Stop the engine and remove the oil pressure gauge and the adapter.

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  7. Install the oil pressure switch.

    8. Tighten
    Tighten the oil pressure switch to 40 N•m (30 lb-ft).

  8. Connect the electrical connector to the oil pressure switch.
  9. Install the right-hand wheel well splash shield
  10. Check the oil level and fill the oil to the FULL mark.

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Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover"in this section.
  4. Disconnect the oil pressure switch connector.

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  5. Remove the crankshaft position (CKP) sensor bolt.
  6. Remove the CKP sensor.
  7. Remove the oil pan. Refer to "Oil Pan"in this section.
  8. Remove the oil pump pickup tube and the support bracket bolts.
  9. Remove the oil pump pickup tube.

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  10. Remove the oil pump retaining bolts.
  11. Carefully separate the oil pump and the gasket from the engine block and the oil pan.
  12. Remove the oil pump.

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Inspection Procedure

  1. Clean the oil pump and the engine block gasket mating surfaces.
  2. Remove the safety relief valve bolt.
  3. Remove the safety relief valve and the spring.
  4. Remove the oil pump-to-crankshaft seal.

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  5. Remove the oil pump rear cover bolts.
  6. Remove the rear cover.

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  7. Clean the oil pump housing and all of the parts.
  8. Inspect all of the parts for signs of wear. Refer to "Engine Specifications"in this section.
  9. Coat all of the oil pump parts with clean engine oil.
  10. Reinstall all of the oil pump parts.

    11. Notice : Pack the oil pump gear cavity with petroleum jelly to ensure an oil pump prime. Failure to do this can damage the engine.

  11. Install the oil pump rear cover and the bolts.

    12. Tighten
    Tighten the oil pump rear cover bolts to 6 N•m (53 lbin).

  12. Install the safety relief valve, the spring, the washer, and the bolt.

    13. Tighten
    Tighten the oil pump safety relief valve bolt to 30 N•m (22 lb-ft).


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Installation Procedure

  1. Apply a bead of room temperature vulcanizing (RTV) sealer to the oil pump gasket.
  2. Install a new oil pump gasket to the oil pump.
  3. Coat the threads of the oil pump bolts with Loctite® 573.
  4. Install the oil pump to the engine block with the bolts.

    5. Tighten
    Tighten the oil pump retaining bolts to 10 N•m (89 lb-in).


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  5. Install a new oil pump to the crankshaft shaft seal.
  6. Coat the lip of the seal with a thin coat of grease.

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  7. Coat the threads of the oil pump pickup tube and the support bracket bolts with Loctite® 573.
  8. Install the oil pump pickup tube and the bolts.

    9. Tighten
    Tighten the oil pump pickup tube and the support bracket bolts to 10 N•m (89 lb-in).


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  9. Install the oil pan. Refer to "Oil Pan"in this section.
  10. Install the CKP sensor and the bolt.

    11. Tighten
    Tighten the crankshaft position sensor retaining bolt to 10 N•m (89 lb-in).

  11. Connect the oil pressure switch connector.
  12. Install the rear timing belt cover. Refer to "Rear Timing Belt Cover"in this section.
  13. Install the timing belt. Refer to "Timing Belt" In this section.
  14. Connect the negative battery cable.

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Oil Pan

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Drain the engine oil from the engine crankcase.
  3. Disconnect the rear heated oxygen (HO2S) sensor.
  4. Remove the catalytic converter upper flange nuts from the exhaust manifold and the bolts from the bracket.

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  5. Remove the nuts from the front muffler pipe to the connecting pipe.

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  6. Remove the oil pan retaining bolts.
  7. Remove the oil pan from the engine block.

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Cleaning Procedure

  1. Clean the oil pan sealing surface.
  2. Clean the engine block sealing surface.
  3. Clean the oil pan retaining bolts.
  4. Clean the oil pan retaining bolt holes in the engine block.

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Installation Procedure

  1. Install the oil pan gasket to the oil pan.
  2. Install the oil pan to the engine block.

    3. Important : Install the oil pan within 5 minutes after applying liquid gasket to the oil pan.

  3. Install the oil pan retaining bolts.

    4. Tighten
    Tighten the oil pan retaining bolts to 10 N•m (89 lb-in).


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  4. Install the catalytic converters.

    5. Tighten
    Tighten the catalytic converter-to-exhaust manifold nuts and bracket bolts to 40 N•m (30 lb-ft).


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    Tighten
    Tighten the front muffler-to-connecting pipe nuts to 30 N•m (22 lb-ft).

  5. Connect the rear heated oxygen sensor connector.

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  6. Connect the negative battery cable.
  7. Install the oil pan drain plug.

    8. Tighten
    Tighten the oil pan drain plug to 35 N•m (25 lb-ft).

  8. Refill the engine crankcase with engine oil.

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Engine Mount

Tools Required

J-28467-B Engine Assembly Support Fixture

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner housing bolts and the air filter housing assembly.
  3. Support the engine assembly using the engine assembly support fixture J-28467-B.

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  4. Remove the engine mount bracket retaining bolts.

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  5. Remove the engine mount attaching nuts.
  6. Remove the engine mount.

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Installation Procedure

  1. Install the engine mount.
  2. Install the engine mount attaching nuts.

    3. Tighten
    Tighten the engine mount attaching nuts to 40 N•m (30 lb-ft).


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  3. Install the engine mount bracket retaining bolts.

    4. Tighten
    Tighten the engine mount bracket retaining bolts to 65 N•m (48 lb-ft).


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  4. Remove the engine assembly support fixture J-28467-B.
  5. Connect the negative battery cable.

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Intake Manifold

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery cable.
  4. Disconnect the engine control module (ECM) ground terminal from the intake manifold.

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  5. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  6. Disconnect the intake air temperature (IAT) sensor connector.
  7. Disconnect the air intake tube from the throttle body.

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  8. Disconnect the idle air control valve (IAC) connector.
  9. Disconnect the throttle position (TP) sensor connector..

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  10. Disconnect the heater inlet hose from the coolant distributor beneath the intake manifold.
  11. Disconnect the surge tank coolant hose at the throttle body.
  12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.

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  13. Disconnect the throttle cable from the throttle body and the intake manifold.
  14. Remove the two throttle cable bracket bolts and the throttle cable bracket.
  15. Disconnect the fuel feed line from the fuel rail.

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  16. Disconnect the fuel injector connectors from the fuel injectors.
  17. Remove the two retaining bolts from the fuel injector rail.
  18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Section 1F, Engine Controls.

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  19. Remove the serpentine accessory drive belt.
  20. Remove the alternator bracket and the bolt.

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  21. Remove the three intake manifold support bracket retaining bolts from the coolant distributor and the engine block.
  22. Remove the intake manifold support bracket.

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  23. Remove the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown.

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  24. Remove the intake manifold.
  25. Remove the intake manifold gasket.
  26. Clean the sealing surfaces of the intake manifold and the cylinder head.

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Installation Procedure

  1. Install the intake manifold gasket.
  2. Install the intake manifold.
  3. Install the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown.

    4. Tighten
    Tighten the intake manifold retaining nuts in the sequence shown to 25 N•m (18 lb-ft).
    Tighten the engine lift bracket bolt to 25N•m(18 lb-ft).


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  4. Install the intake manifold support bracket.
  5. Install the intake manifold support bracket retaining bolts.

    6. Tighten
    Tighten the intake manifold support bracket retaining bolts to 22 N•m (16 lb-ft).

  6. Install the alternator bracket and the bolts.

    7. Tighten
    Tighten the alternator bracket retaining bolts to 20 N•m (15 lb-ft).

  7. Install the serpentine accessory drive belt.

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  8. Install the fuel rail and the fuel injectors as an assembly. Refer to Section 1F, Engine Controls.
  9. Install the fuel rail retaining bolts.

    10. Tighten
    Tighten the fuel rail retaining bolts to 25N•m(18 lb-ft).

  10. Connect the fuel feed line to the fuel rail.

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  11. Connect the throttle cable to the intake manifold and the throttle body.
  12. Connect the fuel injector connectors to the fuel injectors.
  13. Connect all of the vacuum lines that were previously disconnected.
  14. Connect the heater inlet hose to the coolant distributor beneath the intake manifold.
  15. Connect the surge tank coolant hose to the throttle body.
  16. Connect the IAC valve connector.
  17. Connect the throttle position sensor connector.

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  18. Connect the air intake tube to the throttle body.
  19. Connect the IAT sensor connector.
  20. Connect the ECM ground terminal to the intake manifold.
  21. Connect the negative battery cable.
  22. Install the fuel pump fuse.
  23. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.

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Exhaust Manifold

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the ignition wires from the spark plugs.
  3. Disconnect the oxygen (O2) sensor.
  4. Remove the exhaust manifold heat shield bolts.
  5. Remove the exhaust manifold heat shield.
  6. Remove the auxiliary catalytic converter upper flange nuts.

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  7. Remove the eight exhaust manifold nuts in the sequence shown.
  8. Remove the exhaust manifold.
  9. Remove the exhaust manifold gasket.
  10. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

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Installation Procedure

  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.
  3. Install the eight exhaust manifold nuts and torque in the sequence shown.

    4. Tighten
    Tighten the exhaust manifold nuts 25 N•m (18 lb-ft).


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  4. Install the catalytic converter-to-exhaust manifold nuts.

    5. Tighten
    Tighten the catalytic converter-to-exhaust manifold nuts to 40 N•m (30 lb-ft).

  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts.

    7. Tighten
    Tighten the exhaust manifold heat shield bolts to 15 N•m (11 lb-ft).

  7. Connect the O2 sensor.
  8. Connect the ignition wires to the spark plugs.
  9. Connect the negative battery cable.

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Camshaft Gear

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Remove the valve cover bolts.
  4. Remove the valve cover.

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    Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  5. While holding the camshaft firmly in place, remove the camshaft gear bolt.
  6. Remove the camshaft gear.

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Installation Procedure

    Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  1. Install the camshaft gear.
  2. While holding the camshaft firmly in place, install the camshaft gear bolt.

    3. Tighten
    Tighten the camshaft gear bolt to 45 N•m (33 lb-ft).


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  3. Install the valve cover.
  4. Install the valve cover bolts.

    5. Tighten
    Tighten the valve cover bolts to 9 N•m (80 lb-in).

  5. Install the timing belt. Refer to "Timing Belt" in this section.
  6. Connect the negative battery cable.

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Rear Timing Belt Cover

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.

    3. Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  3. Remove the camshaft gear. Refer to "Camshaft Gear"in this section.
  4. Remove the timing belt automatic tensioner bolt.
  5. Remove the timing belt automatic tensioner.
  6. Remove the rear timing belt cover bolts.
  7. Remove the rear timing belt cover.

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Installation Procedure

  1. Install the rear timing belt cover.
  2. Install the rear timing belt cover bolts.

    3. Tighten
    Tighten the rear timing belt cover bolts to 10 N•m (89 lb-in).

  3. Install the timing belt automatic tensioner.
  4. Install the timing belt automatic tensioner bolt.

    5. Tighten
    Tighten the timing belt automatic tensioner bolt to 20 N•m (15 lb-ft).

    Notice : Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.

  5. Install the camshaft gear. Refer to "Camshaft Gear" in this section.
  6. Install the timing belt. Refer to "Timing Belt" in this section.
  7. Connect the negative battery cable.

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Engine

Tools Required

KM-470-B Angular Torque Gauge.

Removal Procedure

    Important : On vehicles equipped with a manual transaxle, the manual transaxle must be removed before engine removal. Refer to Section 5B, Five-Speed Manual Transaxle.

  1. Remove the fuel pump fuse. Drain the engine oil.
  2. Start the engine. After it stalls, crank the engine for
  3. Remove the hood. Refer to Section 9R, Body Front End.
  4. Drain the engine oil.

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  5. Disconnect the negative battery cable.
  6. Disconnect and separate the battery positive cable.
  7. Disconnect the negative battery cable from the vehicle frame.

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  8. Discharge the air conditioning (A/C) system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  9. Disconnect the intake air temperature (IAT) sensor connector.
  10. Remove the air intake tube from the throttle body and the air filter housing.
  11. Disconnect the breather tube from the valve cover.

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  12. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  13. Remove the right front wheel well splash shield.
  14. Remove the serpentine accessory drive belt.

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  15. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  16. Remove the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.
  17. Disconnect the upper radiator hose from the thermostat housing.
  18. Disconnect the coolant surge tank hose from the radiator.
  19. Disconnect the power steering return hose from the power steering pump, if equipped.
  20. Drain the power steering system, if equipped.
  21. Disconnect the power steering pressure hose from the power steering pump, if equipped.

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  22. Disconnect the electrical connector at the electronic ignition (EI) system ignition coil, and the engine control module (ECM) ground terminal at the intake manifold and at the starter motor.
  23. Disconnect the pre-converter oxygen (O2) sensor connector.
  24. Disconnect the electrical connectors at the fuel injectors.
  25. Disconnect the idle air control (IAC) valve connector.
  26. Disconnect the throttle position (TP) sensor connector.
  27. Disconnect the coolant temperature sensor (CTS) connector and the knock sensor, if equipped.

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  28. Disconnect the alternator voltage regulator connector.
  29. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  30. Disconnect the fuel feed line at the fuel rail.
  31. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
  32. Disconnect the camshaft position (CMP) sensor connector.

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  33. Disconnect the surge tank coolant hose at the throttle body.
  34. Disconnect the heater inlet hose from the coolant distributor.
  35. Disconnect the heater outlet hose at the coolant pipe.
  36. Disconnect the surge tank coolant hose from the coolant pipe.
  37. Disconnect the lower radiator hose at the coolant pipe.

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  38. Disconnect the starter solenoid "S" terminal wire.
  39. Remove the A/C compressor hose assembly retaining bolt.
  40. Disconnect the A/C compressor hose assembly from the compressor.
  41. Disconnect the A/C compressor coil connector.
  42. Remove the A/C compressor mounting bolts.
  43. Remove the A/C compressor.
  44. Remove the A/C compressor mounting bracket bolts.
  45. Remove the A/C compressor mounting bracket from the engine block.

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  46. Remove the catalytic converter nuts from the exhaust manifold.

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  47. Remove the nuts from the front muffler pipe to the connecting pipe.

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  48. Remove the engine crankshaft pulley bolt.
  49. Remove the engine crankshaft pulley.

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  50. Disconnect the vacuum lines at the evaporative (EVAP) emission canister purge.
  51. Disconnect the electrical connector at the EVAP emission canister purge solenoid and the knock sensor.
  52. Disconnect the electrical connector at the oil pressure switch.
  53. Disconnect the crankshaft position (CKP) sensor connector and the CMP sensor connector.
  54. Remove the CKP sensor retaining bolt.
  55. Remove the CKP sensor.

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  56. Remove the battary with the nut.
  57. Remove the battary tray.
  58. Remove the right transaxle brace bolts from the transaxle.
  59. Disconnect the back up switch connector.
  60. Remove the hydranlic clutch pipe. Refer to Section 5C, Clutch

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  61. Remove the transaxle bell housing bolts.
  62. Support the transaxle with a floor jack.
  63. Inatall the engine lifting device.
  64. Disconnect the right engine mount bracket from the rubber engine mount by removing the two retaining bolts.
  65. Remove the right engine mount bracket from the engine block.
  66. Separate the engine block from the transaxle.
  67. Remove the engine.
  68. Transfer any necessary parts.

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Installation Procedure

  1. Install the engine into the engine compartment.
  2. Align the transaxle alignment pins to the transaxle.
  3. Install the transaxle bell housing bolts.

    4. Tighten
    Tighten the transaxle bell housing bolts to 75 N•m (55 lb-ft).


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  4. Install the right engine mount bracket to the engine block.
  5. Install the right engine mount bracket retaining bolts to the engine block.

    6. Tighten
    Tighten the engine mount bracket retaining bolts to 60 N•m (44 lb-ft).

  6. Install the engine mount-to-bracket retaining bolts.

    7. Tighten
    Tighten the engine mount bracket-to-engine mount retaining bolts to 60 N•m (44 lb-ft).

  7. Remove the floor jack used for support of the transaxle.
  8. Remove the engine lifting device.

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  9. Install the right transaxle brace bolts to the transaxle.

    10. Tighten
    Tighten the right transaxle brace bolts to 60 N•m (44 lb-ft).

  10. Connect the back up switch electrical connector.
  11. Install the hydraulic clutch pipe.Refer to Section 5C, Clutch
  12. Install the battary tray.
  13. Install the battary with the nut.
  14. Connect the vacuum lines at the EVAP emission canister purge solenoid.
  15. Connect the electrical connectors at the EVAP emission canister purge solenoid.

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  16. Connect the oil pressure switch connector.
  17. Install the crankshaft pulley.
  18. Install the crankshaft pulley bolt.

    19. Tighten
    Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft) using a torque wrench. Using the angular torque gauge KM-470-B, tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.


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  19. Install the CKP sensor and the CKP sensor retaining bolt.

    20. Tighten
    Tighten the crankshaft position sensor retaining bolt to 10 N•m (89 lb-in).

  20. Connect the CKP sensor connector.
  21. Install the nuts from the front muffler pipe to the connecting pipe and catalytic converter.

    22. Tighten
    Tighten the front muffler pipe to the connecting pipe to 30 N•m (22 lb-ft).


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    Tighten
    Tighten the catalytic converter-to-exhaust manifold nuts to 40 N•m (30 lb-ft).


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  22. Connect the power steering pressure hose from the power steering pump.

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  23. Install the A/C compressor mounting bracket, if equipped.
  24. Install the A/C compressor mounting bracket bolts, if equipped.

    25. Tighten
    Tighten the A/C compressor mounting bracket bolts to 50 N•m (37 lb-ft).

  25. Install the A/C compressor, if equipped.
  26. Install the A/C compressor mounting bolts, if equipped.

    27. Tighten
    Tighten the A/C compressor mounting bolts to 27 N•m (20 lb-ft).

  27. Connect the A/C compressor coil connector.
  28. Install the alternator drive belt.
  29. Install the A/C compressor drive belt, if equipped.
  30. Connect the A/C compressor hose assembly and the A/C compressor hose assembly retaining bolt, if equipped.

    31. Tighten
    Tighten the A/C compressor hose assembly retaining bolt to 33 N•m (24 lb-ft).


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  31. Install the right front wheel well splash shield.
  32. Install the right front wheel. Refer to Section 2E, Tires and Wheels
  33. Connect the fuel feed line to the fuel rail.
  34. Connect all of the necessary vacuum lines, including the brake booster vacuum hose.

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  35. Connect the pre-converter O2 sensor connector.
  36. Connect the starter solenoid "S"terminal wire.
  37. Connect the alternator voltage regulator connector.
  38. Connect the CTS connector.
  39. Connect the TP sensor connector.
  40. Connect the IAC valve connector.
  41. Connect the CMP sensor connector.

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  42. Connect the electrical connectors at the fuel injectors.
  43. Connect the electrical connector at the EI system ignition coil and the PCM/ECM ground terminal at the intake manifold.
  44. Install the air intake tube between the throttle body and the air filter housing.
  45. Connect the breather tube to the valve cover.
  46. Connect the IAT sensor connector.

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  47. Install the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.
  48. Connect the lower radiator hose to the coolant pipe.
  49. Connect the upper radiator hose to the thermostat housing.
  50. Connect the coolant surge tank hose to the radiator.
  51. Connect the heater outlet hose to the coolant pipe.
  52. Connect the heater inlet hose to the coolant distributor.
  53. Connect the coolant surge tank hose to the coolant pipe.
  54. Connect the surge tank coolant hose to the throttle body.

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  55. Connect the throttle cable to the throttle body and the intake manifold bracket. Install the fuel pump fuse.
  56. Connect the negative battery cable to the vehicle frame.
  57. Connect the negative battery cable to the battery.
  58. Connect and assemble the battery positive cable.
  59. Refill the engine crankcase with engine oil.
  60. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
  61. Refill the engine coolant system. Refer to Section 6A, Power Steering System.
  62. Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.
  63. Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  64. Install the hood. Refer to Section 9R, Body Front End.

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Pistons and Rods

Tools Required

KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge

Removal Procedure

  1. Remove the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Head and Gasket"in this section.
  2. Remove the oil pan. Refer to "Oil Pan" in this section.
  3. Remove the oil pump/pickup tube bolts.
  4. Remove the oil pump/pickup tube.

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  5. Move the piston to the bottom of the piston stroke.
  6. Mark the connecting rod cap.
  7. Remove the connecting rod cap bolts.
  8. Remove the connecting rod cap and lower connecting rod bearing.
  9. Remove the upper piston connecting rod bearing.
  10. Ridge ream the cylinder wall.

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    Caution : Use care when handling the piston. Worn piston rings are sharp and may cause injury.

  11. Remove the piston.
  12. Use a piston ring expander tool to expand the piston rings.
  13. Remove the piston rings.

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  14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
  15. Separate the piston from the connecting rod.

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Installation Procedure

  1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
  2. Inspect the connecting rod bearings.
  3. Inspect the connecting rod lower end for wear.
  4. Inspect the connecting rod upper end for scoring.
  5. Inspect the piston for scoring, cracks and wear.
  6. Inspect the piston for taper using a micrometer.

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  7. Inspect the piston for fit to the connecting rod.

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  8. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
  9. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to "Engine Specifications" in this section. If beyond specifications, replace the engine block.
  10. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
  11. Inspect the engine block cylinder bore for glazing.

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Installation Procedure

  1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
  2. Install the piston pin guide through the piston and the connecting rod.
  3. Coat the piston pin with clean oil.
  4. Install the piston pin into the opposite side of the piston.
  5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.

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  6. Select a set of new piston rings.
  7. Measure the piston ring gap using a feeler gauge. Refer to "Engine Specifications"in this section.
  8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.

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  9. Measure the piston ring side clearance using a feeler gauge. Refer to "Engine Specifications" in this section.
  10. If the piston ring is too thick, try another piston ring.
  11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.

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  12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
  13. Install the second compression ring to the middle ring groove of the piston.
  14. Install the top compression ring to the top ring groove of the piston.

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  15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
  16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the piston.

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  17. Lubricate the cylinder wall and the piston rings with clean engine oil.
  18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
  19. Install the connecting rod cap and the bearings. Refer to "Crankshaft Bearings and Connecting Rod Bearings -- Gauging Plastic"in this section.

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  20. Install the connecting rod cap bearing bolts.

    21. Tighten
    Tighten the connecting rod bearing cap bolts to 25 N•m (18 lb-ft). Using the angular torque gauge KM-470-B, tighten one turn of 30 degrees plus.


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  21. Install the oil pump/pickup tube.
  22. Install the oil pump/pickup tube bolts.

    23. Tighten
    Tighten the oil pump/pickup tube and support bracket bolts to 10 N•m (89 lb-in).

  23. Install the oil pan. Refer to "Oil Pan"in this section.
  24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket"in this section.in this section.


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