Removal and Replacement

REMOVAL
1. Remove cylinder heads and oil pan.
2. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore.





3. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary (Fig. 83).





4. Remove connecting rod cap. Install protectors on connecting rod bolts (Fig. 84). Push each piston and rod assembly out of cylinder bore.

NOTE: Be careful not to nick crankshaft journals.

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


INSTALLATION

NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts should be replaced.





1. Check connecting rod bolts for necking by holding a scale or straight edge against the threads. If all threads do not contact the scale, the bolt should be replaced (Fig. 85).





2. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 94).





3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 86).
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston and tighten with the special wrench. Ensure position of rings does not change during this operation
5. Position upper bearing shell on connecting rod. Lubricate bearing with clean engine oil.
6. Install connecting rod bolt protectors on rod bolts (Fig. 84).
7. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore.
8. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.

CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank.








9. The arrow on top of piston must be pointing toward front of engine (Fig. 87) and oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore (Fig. 88).
10. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
11. Position lower bearing shell on connecting rod cap. Lubricate bearing with clean engine oil.
12. Install connecting rod cap. Install nuts on cleaned and oiled rod bolts.
13. Measure connecting rod side and bearing clearances.
14. After oil clearance measurement is completed, tighten connecting rod nuts to 54 Nm (40 ft. lbs.) plus 1/4 turn.
15. Install cylinder heads and oil pan.