Removal and Replacement
REMOVALNOTE: Pistons and connecting rods are to be removed as an assembly from top of cylinder block.
1. Remove cylinder heads.
2. Remove oil pan and windage tray.
3. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. (Fig. 78)
4. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 79). 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.
INSPECTION
CONNECTING ROD
1. Check the connecting rods for twist or bend.
2. Check the condition of the large end. Use an oil stone to remove any nicks and burrs.
3. Check the condition of the pin bore in the small end of the connecting rod. Use an oil stone to remove all nicks and burrs.
PISTON PIN
1. Inspect for free rotation of the piston pin in the piston.
PISTON
1. Inspect all piston surfaces for nicks and scuffs.
2. Inspect piston and ring grooves for wear.
INSTALLATION
NOTE: 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. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 87).
1. 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.
2. Install connecting rod bolt protectors on rod bolts.
3. Rotate crankshaft so that the connecting rod journal is at the bottom of it's stroke and in the center of the cylinder bore.
4. The arrow on top of piston must be pointing toward front of engine (Fig. 81).
5. Install piston assembly from the top of the block (Fig. 80). Tap the piston down in cylinder bore, using a hammer handle. Guide the rod over the crankshaft journal.
6. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 85 Nm (62.6 ft. lbs.).
7. Install windage tray and oil pan.
8. Install cylinder heads.