Page 1233 of 4264
ENGINE MECHANICAL 6A – 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
ROCKER ARM SHAFT AND ROCKER ARM
020RY00029
Reassembly Steps
1.
Rocker arm shaft 5.
Rocker arm
2.
Rocker arm shaft snap ring 6.
Rocker arm shaft spring
3.
Rocker arm 7.
Rocker arm shaft snap ring
4.
Rocker arm shaft bracket
Reassembly
1. Rocker Arm Shaft
1. Position the rocker arm shaft with the large oil hole (4
) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft Snap Ring
014RY00037
Page 1234 of 4264
6A – 94 ENGINE MECHANICAL
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1.
Cylinder head 6.
Valve spring upper seat
2.
Valve spring lower seat 7.
Split collar
3.
Valve stem oil seal 8.
Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5.
Valve spring
Page 1235 of 4264

ENGINE MECHANICAL 6A – 95
Reassembly
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
6. Valve Spring Upper Seat
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
RTW46ASH002301
8. Intake manifold gasket
9. Intake manifold
1. Install the manifold gasket with the end having the
sharp corners facing the rear of the engine.
2. Install the intake manifold to the cylinder head.
3. Tighten the manifold bolt/nuts to the specified torque.
Manifold Bolt/Nut Torque N·m(kg·m/lbft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
011RW027
011LX055
014RY00039
Page 1236 of 4264
6A – 96 ENGINE MECHANICAL
PISTON AND CONNECTING ROD
RTW46ALF000301
Reassembly Steps
1.
Piston 5.
Piston pin snap ring
2.
Connecting rod 6.
Piston ring
3.
Piston pin snap ring 7.
Connecting rod bearing
4.
Piston pin
Page 1237 of 4264
ENGINE MECHANICAL 6A – 97
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
RTW36ASH001801
Install the piston to the connecting rod so that the piston
head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
3. Piston Pin Snap Ring
RTW36ASH001901
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
5. Piston Pin Snap Ring
1. Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the
piston pin.
F06MV015
015R100001
Page 1238 of 4264
6A – 98 ENGINE MECHANICAL
RTW36ASH002001
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the
piston ring grooves
7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
015R100006
Page 1239 of 4264
ENGINE MECHANICAL 6A – 99
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
RTW46AMF000101
Reassembly Steps
1. Positive Crankcase Ventilation
(PCV) Valve 5.
Fixing bolt
2.
Rubber space 6.
Oil filler cap
3.
Cylinder head insulator cover
4.
Breather pipe
Page 1240 of 4264
6A – 100 ENGINE MECHANICAL
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
PCV Valve Bolts Torque N·m(kg·m/lb in)
2 (0.2/17)
2. Rubber Spacer
3. Cylinder Head Insulator Cover
RTW36ASH001401
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
Fixing Bolt Torque N·m(kg·m/lb in)
19 (1.9/14)
6. Oil Filler Cap
010R100014