Piston, Pin, Connecting Rod

REMOVAL





1. Remove the left side cover.





2. Remove the oil screen.
3. Remove the baffle plate.
4. Remove the oil pass pipe and joint.
5. Remove the oil pump.





6. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer. Follow reamer manufacturer's instructions.

CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out.





7. Remove the bearing cap bridge.
- Remove the connecting rod caps after setting the crank pin at Bottom Dead Center (BDC) for each cylinder. Remove the piston assembly by pushing on the connecting rod.





CAUTION: Take care not to damage the crank pin or cylinder with the connecting rod.

8. Remove the bearing from the cap. Keep all caps/bearings in order.
9. Remove the upper bearing halves from the connecting rods. Set them aside with their respective caps.
10. Reinstall the cap on the rod after removing each piston/connecting rod assembly.
11. Mark the piston/connecting rod assemblies with their cylinder numbers to avoid mix-up on reassembly.

NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.





12. Remove the bearing cap bolts and bearing cap side bolts, then remove the bearing caps.





- To help with removal of the caps, install the bearing cap bridge bolts in the bearing cap bolt holes.





13. Lid the crankshaft out of engine, being careful not to damage the journals.
14. Reinstall the main caps and bearings on the block in proper order.

INSTALLATION

NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.





1. If the crankshaft is already installed:
- Guide the piston carefully to prevent damage.
- Fit long rubber hoses (about 30 cm (12 inch) long) to the connecting rod bolts to protect the crankshaft. Install the pistons after setting the crankshaft to Bottom Dead Center (BDC) for each cylinder.
- Install the piston assemblies in No. 1 and No. 4 cylinders, No. 2 and No. 5 cylinders, and No. 3 and No. 6 cylinders.
- Install the ring compressor, check that the bearing is securely in place; then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
- Stop after the ring compressor pops free and check the connecting rod-to-crank journal alignment before putting rod into place.
- Install the rod caps with bearings, and torque the nuts to 20 Nm (14 lbs. ft), then turn the nut 116 degrees.





2. If the crankshaft is not installed:
- Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.





NOTE: Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore.