Removal and Installation

REMOVAL

NOTE: Cylinder Head must be removed before Pistons and Rods. Refer to Cylinder Head Removal.

Figure 92:

1. 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. Mark piston with matching cylinder number (Fig. 92).

Figure 93:

2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap (Fig. 93) for identification.
3. Pistons have a directional stamping in the front half of the piston facing towards the front of engine.
4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
5. Remove Balance Shaft Assembly. Refer to Balance Shaft Removal.
6. Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore.

NOTE: Be careful not to nick crankshaft journals.

7. After removal, install bearing cap on the mating rod.
8. Piston and Rods are serviced as an assembly.

INSTALLATION
1. 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.

Figure 94:

2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown (Fig. 94). As viewed from top.

Figure 95:

3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 95). Be sure position of rings does not change during this operation.

Figure 92:

4. The directional stamp on the piston should face toward the front of the engine.
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly 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 connecting rod journal.

NOTE: The connecting rod cap bolts should not be reused.

7. Before installing the NEW bolts the threads should be coated with clean engine oil.
8. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly.

CAUTION: Do not use a torque wrench for second part of last step.

9. Tighten the bolts to 27 Nm PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn).

Figure 96:

10. Using a feeler gauge, check connecting rod side clearance (Fig. 96).