Removal and Replacement

PISTON & CONNECTING ROD

REMOVAL
1. Disconnect negative cable from battery.
2. Remove the cylinder heads.
3. Remove the oil pan.
4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, 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.

Fig.78:

5. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary (Fig. 78).

Fig.79:

6. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 79).
7. Remove each piston and connecting rod assembly out of the cylinder bore.

NOTE: Be careful not to nick crankshaft journals.

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

INSTALLATION

Fig.80:

1. 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. 80).
2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 80).

Fig.81:

3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor (Fig. 81). Be sure position of rings does not change during this operation.
4. Position upper bearing onto connecting rod. Lubricate bearing with oil.
5. Install connecting rod bolt protectors (rubber hose or equivalent) on the connecting rod bolts (Fig. 81).

Fig.82:

6. The pistons are marked with a "F" located near the piston pin. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block (Fig. 82).
7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore. Carefully guide connecting rod over the crankshaft journal (Fig. 81).
8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
9. Install lower bearing shell and connecting rod cap (Fig. 81). Install nuts on cleaned and oiled rod bolts and tighten to 54 Nm (40 ft. lbs.) PLUS 1/4 turn.
10. Repeat procedure for each piston and connecting rod installation.
11. Install the cylinder heads.
12. Install the oil pan.
13. Fill engine crankcase with proper oil to correct level.
14. Connect negative cable to battery.