Removal and Replacement

REMOVAL
1. Remove oil pan and cylinder head(s).





Fig. 99

2. Identify pistons with matching cylinder. The pistons are not interchangeable from bank to bank (Fig. 99). Pistons with the letter R and arrow toward the front of engine are to be installed in cylinders 1-3-5. Pistons with the letter L and arrow toward the front of engine are to be installed in cylinders 2-4-6.





Fig. 100

3. Mark connecting rod and cap with cylinder number (Fig. 100).





Fig. 101

4. Remove piston rings (Fig. 101).

INSTALLING PISTON RINGS





Fig. 102

1. The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers mark and size mark facing up, to the top of the piston (Fig. 102).

CAUTION: Install piston rings in the following order:

a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.





Fig. 103

2. Install the side rails (upper rail first, then lower rail) by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do Not use a piston ring expander (Fig. 103).





Fig. 104

3. Using a piston ring expander, install No. 2 piston ring and then No. 1 piston ring (Fig. 104).





Fig. 105

4. Position piston ring end gaps as shown in (Fig. 105).
5. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction.

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.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 105).
3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston and tighten. Be sure position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
6. Install the piston and connecting rod assembly with the directional letter is located on the top of the piston with the arrow facing toward the camshaft sprocket.





Fig. 106

7. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal (Fig. 106).
8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 52 Nm (38 ft. lbs.).

CAUTION: Piston assemblies are not to be interchanged from bank to bank.





Fig. 107

9. Check alignment marks made during disassembly and that bearing position notches new or used are on the same side as shown in (Fig. 107).
10. Install cylinder head(s) and oil pan.