Removal and Replacement
ROD-PISTON & CONNECTINGREMOVAL
NOTE: Pistons and connecting rods are to be removed as an assembly from top of cylinder block.
1. Remove engine and place in a suitable engine stand.
2. Remove cylinder heads.
3. Remove oil pan.
4. Remove the oil pump pick up tube (2)
5. Remove the crankshaft oil scraper nuts (1) and oil scraper (2).
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
6. Inspect connecting rods and connecting rod caps for cylinder identification (1). Identify them if necessary using a permanent ink or paint marker.
CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur.
NOTE: Do not reuse connecting rod bolts.
7. Remove connecting rod bolts and cap. Push each piston and rod assembly out the block.
NOTE: Be careful not to nick crankshaft journals.
8. 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: Pistons and connecting rods are serviced as an assembly. Left bank pistons are labeled ODD. Right bank pistons are labeled EVEN.
1. Install piston rings.
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.
2. 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.
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 (1) must be pointing toward front of engine.
5. Install new connecting rod bearing in connecting rod and rod cap.
6. Install piston assembly from the top of the block. Tap the piston down in cylinder bore, using a hammer handle. Guide the rod over the crankshaft journal.
7. Install rod cap. Install NEW connecting rod bolts. Bolt threads should be oiled with engine oil. Torque connecting rod bolts to 68 Nm (50 ft. lbs.).
8. Install the crankshaft oil scraper (2) and nuts (1). Torque nuts (1) to 23 Nm (200 inch lbs.).
9. Install oil pump pick up tube (2) using a new O-ring (4). Torque 1/4-20 bolt to 11 Nm (95 inch lbs.). Torque 5/16-18 nuts to 23 Nm (200 inch lbs.).
10. Install oil pan.
11. Install cylinder heads.
12. Install engine.