1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.



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 in Engine Exhaust.



7. Remove the following components from the vehicle:

•	Sixteen bolts

•

Two nuts

•	The Crankshaft Sensor (6)

•	The engine oil pan (1)

8. Remove the following components from the cylinder block:

•	The bracket bolt to the oil pump strainer

•	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. Refer to Timing Belt Replacement in Engine Mechanical.
11. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Replacement in Engine Mechanical.
12. Remove the exhaust manifold from the cylinder head. Refer to Exhaust Manifold Replacement in Engine Mechanical.
13. Remove the cylinder head from the block. Refer to Cylinder Head Replacement in Engine Mechanical.



14. Mark the cylinder number on all of the pistons, on all of the connecting rods, and on all of the bearing caps.

Important: Disassemble all of the parts by cylinder.When you reassemble the parts, return all of the parts 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: Before attempting to remove the piston from the cylinder, decarbon the top of the cylinder bore.

17. Remove the piston and the connecting rod assembly out through the top of the cylinder bore.

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 (1).
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 , so that the tool 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 in order to install the piston into the cylinder bore.



8. Install the lower connecting rod bearing to the connecting rod cap.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

9. Install the connecting rod cap (1) to the connecting rod, and secure the cap with two connecting rod cap nuts.

Tighten
Tighten the connecting rod cap nuts to 35 N·m (26 lb ft).




10. Install a new cylinder head gasket (2) with the TOP mark facing towards the cylinder head.
11. Install the cylinder head. Refer to Cylinder Head Replacement .
12. Install the timing belt. Refer to Timing Belt Replacement .
13. Install the intake manifold. Refer to Intake Manifold Replacement .
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement .
15. Install the oil pump strainer and the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical.



16. Install the gasket for the engine oil drain plug and for the drain plug.

Tighten
Tighten the engine oil drain plug to 35 N·m (26 lb ft).

17. Connect the negative battery cable.
18. Refill the engine oil to specifications. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.
19. Start the engine. Inspect the exhaust system for exhaust leaks.
20. Run the engine in order to inspect the engine oil pressure.