Piston and Connecting Rod - Removal

REMOVAL





1. Perform the fuel system pressure release procedure Service and Repair.
2. Disconnect and isolate the negative battery cable (3).





3. Remove the engine covers (1).





4. Loosen clamp and disconnect air duct at throttle body.
5. Disconnect intake air temperature sensor (4) electrical connector.
6. Remove makeup air hose (1).
7. Remove air cleaner housing retaining bolt (3) and remove air cleaner housing (2).
8. Remove the cylinder head(s) Cylinder Head - Removal.
9. Raise and support the vehicle.





10. Remove the engine mount nuts (1,2).





11. Remove the steering gear mounting bolts (1) and position the steering gear (2) aside.
12. Remove the engine oil dipstick and tube from the oil pan.
13. Lower the vehicle.






NOTE: Do not use air tools to install engine lift fixture.

14. Install the Engine Lift Fixture 8984A (1), Engine Lift Adapter 8984-UPD (2) and the Engine Support Fixture 8534B (3).
15. Raise the engine to provide clearance to remove the oil pan.
16. Raise and support the vehicle.
17. Remove the oil pan Engine Oil Pan - Removal.
18. Lower the vehicle.
19. Remove the timing chain cover Engine Timing Cover(s) - Removal.
20. If necessary, remove the ridge on top of the cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation.






CAUTION: Do Not use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur.

NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

21. Raise and support the vehicle.
22. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool.






CAUTION: When removing and installing the piston and connecting rod assembly, Do Not damage the piston oil cooler jets (1). If the jets are bent, engine damage may occur.

CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.

CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.

NOTE: Pistons and connecting rods assemblies must be removed from the top of cylinder block. When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft so each connecting rod is centered in the cylinder bore.

23. Remove the connecting rod cap and carefully remove the piston from the cylinder bore, repeat this procedure for each piston being removed.
24. Immediately after removing the piston and connecting rod, install the bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
25. Carefully remove the piston rings from the piston(s), starting from the top ring down.