Removal and Installation

PISTON

REMOVAL

1. Pistons and connecting rods and cylinder liners are to be removed as a assembly from top of cylinder block.






2. Install liner clamps Special Tool 6629 on the cylinders not being removed . This will prevent the liners from moving in their bores when rotating the crankshaft.







3. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary.






4. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out the bottom of cylinder liner.

NOTE: Be careful not to nick crankshaft journals.

5. After removal, install bearing cap on the matching rod.




INSTALLATION

1. Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.







2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located.

3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation.







4. Install piston assembly from the bottom of liner. Tap the piston down in cylinder liner, using a hammer handle.







5. Install connecting rod bolt protectors on rod bolts.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. Notch in bottom of liner must face toward outside of cylinder block.







7. The arrow on top of piston must be pointing toward front of engine.
8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lb.).