Removal and Replacement
PISTON & CONNECTING RODREMOVAL
1. Disconnect the negative battery cable.
2. Remove the engine.
3. Remove the cylinder head.
4. Remove the oil pan.
5. Push back on the chain tensioner and remove the oil pump chain from the oil pump.
6. Remove the oil pump.
NOTE: Mark the connecting rod and connecting rod bearing cap to each other at the inlet side.
7. Remove the connecting rod bearing can.
NOTE: Do Not mix up the top and bottom connecting rod bearing shells.
8. Mark the connecting rod bearing shell and the connecting rod bearing cap to each other.
NOTE: If the pistons are used, the direction of travel arrows and the marking of the pistons may no longer be visible because of carbon deposits. The carbon deposits on the pistons must be removed.
NOTE: If the arrows indicating the driving direction on the piston are no longer visible, they must be marked again.
9. Remove the connecting rod together with the piston through the top of the engine.
NOTE: DO NOT mix up the top and bottom connecting rod bearing shells.
10. Mark the connecting rod bearing shell and connecting rod to each other.
CAUTION: Care must be taken not to damage the piston.
11. Remove the piston pin circle clip. (Fig. 39).
12. Press the piston pin out of the piston and connecting rod bushing. (Fig. 39).
13. Inspect the connecting rod for wear and damage.
INSTALLATION
1. Assign piston to the cylinder bore.
2. Using the appropriate clean engine oil, oil piston pin and connecting rod bushing.
CAUTION: Assemble the piston and connecting rod so that the arrow is pointing in the direction of travel (in the opposite direction of power flow). The marking on the connecting rod is pointing toward the inlet side.
3. Assemble piston and connecting rod (Fig. 40).
4. Insert piston pin by hand (Fig. 40).
CAUTION: Care must be taken not to damage the piston.
5. Insert circle clip of piston pin into groove on piston (Fig. 40).
6. Using the appropriate clean engine oil, clean the cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons.
CAUTION: Offset the piston ring gaps by 120°.
7. Position a ring compressor over piston and rings. Tighten ring compressor (Fig. 41). Ensure that ring position does not change during this operation.
CAUTION: Rotate the crankshaft sufficiently so that the connecting rod does not touch the connecting rod journal when the piston is pushed onto the cylinder bore.
8. Install piston with arrow pointing in the direction of travel (in the opposite direction to power flow) (the marking on the connecting rod should be pointing toward the inlet side). (Fig. 41).
9. Clean and inspect the connecting rod bolts.
CAUTION: Assure that the correct top and bottom connecting rod bearings shells are used in accordance with the markings.
CAUTION: The anti-twist locks of the connecting rod bearing shells must be located in the slots of the connecting rod bearing caps.
10. Insert connecting rod bearing shell into connecting rod bearing cap.
CAUTION: The markings on the connecting rod and connecting rod cap must be lined up.
11. Install connecting rod bearing cap. Tighten bolts in 3 stages, 5 Nm (44 inch lbs.), 25 Nm (221 inch lbs.), 90°.
12. Rotate crankshaft fully and check the clearance.
13. Install oil pump.
14. Install engine oil pan and oil pan drain plug.
CAUTION: Install a cylinder head gasket of standard thickness or a cylinder head gasket of repair thickness depending on piston protrusion.
15. Measure piston protrusion.
16. Install cylinder head.
17. Install engine.
18. Fill the crankcase with correct engine oil, to proper level. Refer to owners manual for specifications.
19. Fill the cooing system with proper coolant, to the proper level.
20. Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS, OR FAN. DO NOT WEAR LOOSE CLOTHES.
WARNING: (Refer to FUEL SYSTEM WARNING).
21. Start the engine and inspect for leaks.