Removal and Replacement
REMOVAL1. Remove the engine from the vehicle.
2. Remove the valve cover, rocker arms, push rods and cylinder head. Mark parts as removed.
3. Remove the oil pan and oil pump pick-up tube.
4. 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.
5. Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
6. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. DO NOT try to remove black coating on skirt. This is the dry film lubricant.
7. After removal, install bearing cap on the mating rod.
INSTALLATION
1. Check the crankshaft connecting rod journal for excessive wear, taper and scoring.
2. Check the cylinder block bore for out-of-round, taper, scoring and scuffing.
3. Be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.
Fig. 69
4. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 69).
5. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation.
6. Install connecting rod bolt protectors on rod bolts, a long protector should be installed on the numbered side of the connecting rod.
Fig. 70
7. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore in the bottom dead center position. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore. Be sure the piston and rod assemblies are installed in the proper orientation (Fig. 70).
8. The notch, groove or arrow on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet.
9. While tapping the piston down in cylinder bore with the handle of a hammer, guide the connecting rod over the crankshaft journal.
10. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque.
11. Install the oil pump pick-up tube and oil pan.
12. Install the cylinder head, push rods, rocker arms and valve cover.
13. Install lower intake manifold.
14. Install the engine into the vehicle.