Removal and Installation

REMOVAL
1. Remove the engine from the vehicle.
2. Remove the cylinder head.
3. Remove the oil pan.
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 each connecting rod and connecting rod cap is 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 the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals.
7. After removal, install bearing cap on the mating rod.

INSTALLATION
1. Be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap.

Proper Ring Installation:

2. Before installing the ring compressor, be sure the oil ring expander ends are butted and the rail gaps located properly.
3. 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.
4. Install connecting rod bolt protectors on rod bolts. The long protector should be installed on the numbered side of the connecting rod.
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal.
7. The notch, or groove, 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.
8. Install rod caps. Be sure connecting rod, connecting rod cap, and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque.
9. Install the oil pan.
10. Install the cylinder head.
11. Install the engine into the vehicle.