Removal and Installation
REMOVAL1. Remove RH and LH cylinder heads (6049).
2. Remove and discard head gaskets (6051).
3. If cylinder heads are to be serviced, refer to Cylinder Head Assembly.
4. Remove oil pan (6675) and oil pan gasket (6710).
5. Remove oil pump and oil pump screen cover and tube (6622).
6. Turn crankshaft (6303) until piston to be removed is at the high point of its travel. If more than one piston is being removed, identify the pistons, connecting rods and connecting rod caps for cylinder position.
NOTE:
^ Pistons (6108), connecting rods (6200)and connecting rod bearings (6211) should be numbered to make sure they are assembled in their original positions.
^ Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Rotunda Cylinder Ridge Reamer 014-00292 or equivalent.
7. Remove the connecting rod cap and lower connecting rod bearing. Keep cap and lower connecting rod bearing together. Push the piston connecting rod assembly and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the bearing and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.
CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces. Possible damage to the engine may occur.
NOTE: Connecting rod bolts (6214) are retained in the bolt hole with a light press fit. The connecting rod bolts have been torqued to yield at least twice and must be discarded. Use a hammer and punch to drive connecting rod bolts from connecting rod cap.
8. Using a new connecting rod bolt, attach cap and lower connecting rod bearing to connecting rod and upper bearing to prevent mixing parts and damaging the fractured joint face surfaces.
9. Clean and inspect piston, connecting rod, connecting rod bearings and cylinder block bores.
10. If required, disassemble piston from connecting rod.
11. If required, replace piston rings.
INSTALLATION
1. Coat piston bores, pistons and rings, crankshaft journal and bearing surfaces with clean engine oil.
2. Turn crankshaft until the crankshaft throw is at bottom of stroke. Install correctly numbered piston and connecting rod assemblies with Piston Ring Compressor D81L-6002-C or equivalent and a suitable connecting rod guide tool.
CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Push piston down until connecting rod bearing seats on crankshaft journal.
NOTE:
^ Make sure piston ring gaps are rotated 30 degrees apart.
^ Notch on piston to front of engine.
3. Alternately tighten new connecting rod cap bolts in several passes to obtain 40-45 Nm (30-33 ft. lbs.) and rotate connecting rod bolts an additional 90-120 degrees. After installation, rotate crankshaft to ensure smooth operation.
NOTE: Due to the use of a cracked connecting rod joint face surface, the connecting rod cap must be properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs should be located on the same side of the connecting rod.
4. Check connecting rod side clearance using Dial Indicator with Bracketry TOOL-4201-C or equivalent. Clearance should be 0.15-0.45 mm (0.006-0.0177 inch). If side clearance is greater than maximum service limit of 0.50 mm (0.020 inch), replace connecting rods and /or crankshaft.
5. Install oil pump screen cover and tube.
NOTE: Install new O-ring on oil pump screen cover and tube and then start all bolts on oil pump (6600) and oil pump screen cover and tube before tightening.
6. Install oil pan with new oil pan gasket.
7. If cylinder heads are to be serviced, refer to Cylinder Head Assembly.
8. Clean cylinder head gasket surface with a toluene-based paint thinner or gasket remover. If gasket material remains on head after cleaning, use a 600 grit sandpaper to remove remaining material.
CAUTION: Do not use sandpaper coarser than 600 grit as damage to the cylinder head gasket surface may occur.
9. Position new head gaskets on cylinder head.
NOTE: RH and LH head gaskets are not interchangeable.
10. Rotate crankshaft to position as shown.
CAUTION: Failure to position crankshaft as shown will cause damage to pistons and/or valve train components.
NOTE: With crankshaft in this position, no piston will be at top dead center (TDC).
11. Install cylinder heads.
CAUTION: Use care when positioning cylinder heads. Damage to cylinder blocks (6010) or cylinder heads may result.