Removal and Replacement
PISTON & CONNECTING RODSREMOVAL
1. Remove the cylinder heads.
2. Remove the oil pan.
3. 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.
CAUTION: DO NOT stamp the connecting rods for cylinder identification
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them with a paint mark or scribe, if necessary
5. Remove connecting rod cap. Install protectors, special tool 8189, on connecting rod. Guide each piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.
INSTALLATION
1. Install the piston rings.
NOTE: The connecting rod bearing cap bolts must be examined before reuse. If the threads are necked down, the bolts must be replaced.
2. 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 must be replaced.
3. 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.
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. Install connecting rod bolt protectors, special tool # 8189.
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert the rod and piston into cylinder bore and guide the rod over the crankshaft journal.
CAUTION: Do Not interchange piston assemblies cylinder-to-cylinder or bank-to-bank.
7. The arrow on top of piston must be pointing toward front of engine.
CAUTION: View of connecting rod oil squirt hole is from the front of the engine.
8. The oil squirt hole on connecting rod faces the major thrust (right) side of the cylinder bore.
9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
NOTE: Connecting rod bolts must be lubricated with clean engine oil.
10. Install the rod caps. Install cleaned and inspected connecting rod bolts and tighten to 27 Nm (20 ft. lbs.) Plus 1/4 turn.
11. Install the cylinder head(s).
12. Install the oil pan.