Removal and Replacement

NOTE: Pistons and connecting rods are to removed as an assembly from top of cylinder block.

REMOVAL
(1) Remove cylinder head covers, rocker arms, push rods, and cylinder heads. Identify components as they are removed, to ensure installation in original locations.
(2) Remove oil pan and windage tray.





Fig. 89

(3) Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary (Fig. 89).





Fig. 90

(4) Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 90). Push each piston and rod assembly out the block.

NOTE: Be careful not to nick crankshaft journals.

(5) After removal, install bearing cap on the mating rod.

Fitting Rings





Fig. 91

(1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 91). Refer to Engine, Specifications for piston ring specifications.





Fig. 92

(2) Check piston ring side clearance (Fig. 92). Refer to Engine, Specifications for piston ring specifications.

Installing Piston Rings





Fig. 93

The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers I.D. mark facing up, to the top of the piston (Fig. 93).

CAUTION: Install piston rings in the following order:
(1) Oil ring expander.
(2) Lower oil ring side rail.
(3) Upper oil ring side rail.
(4) No. 2 intermediate piston ring.
(5) No. 1 upper piston ring.





Fig. 94

(6) Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. (Fig. 94).
(7) Install lower side rail first and then the upper side rail.





Fig. 95

(8) Install No. 2 piston ring and then No. 1 piston ring (Fig. 95).





Fig. 96

(9) Position piston ring end gaps as shown in (Fig. 96).
(10) Position oil ring expander gap at least 450 from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

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.





Fig. 96

(2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 96).
(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.





Fig. 97

(4) Install piston assembly from the top of the block (Fig. 97). Tap the piston down in cylinder bore, 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.





Fig. 98

(7) The arrow on top of piston must be pointing toward front of engine (Fig. 98).
(8) Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 85 Nm (62.5 ft. lbs.).
(9) Install windage tray and oil pan.
(10) Install cylinder heads, push rods, rocker arms, and cylinder head covers.