Disassembly and Assembly

DISASSEMBLY

CAUTION:
Component Location/Orientation
The location and orientation of each precision machined component should be noted. When engine is assembled each component should be installed in its original position. These components include:
- Rocker arms, rocker arm seats and valve tappets.
- Crankshaft main bearings and bearing caps.
- Connecting rod bearings and bearing caps.
- Pistons, piston rings and piston pins.
- Camshafts and camshaft journals.

1. Remove pistons and connecting rods.
2. Remove piston rings from pistons.

WARNING: COVER THE END OF THE PIN BORE WITH A HAND OR SHOP RAG WHEN REMOVING THE RETAINER RING SINCE IT HAS A TENDENCY TO SPRING OUT. EYE PROTECTION SHOULD BE WORN.





3. Using O-ring Remover T71P-19703-C, remove the two piston pin retainer rings.





4. Gradually heat pistons to approximately 70-135°C (160-275°F).





5. Using Piston Pin Tool D81L-6135-A or equivalent, press piston pin from piston and connecting rod.

ASSEMBLY
1. Clean and inspect pistons.
2. Clean and inspect connecting rod.
3. Verify that all parts to be assembled are for same cylinder.

NOTE: When installing piston pin, check each end of piston pin for identification mark. If identification mark is present, install piston pin with identification mark toward front of engine.

NOTE: Connecting rods may be installed into pistons with connecting rod identification mark in either direction.

4. Install new piston pin retainer ring into one side of piston pin bore.
5. Gradually heat pistons to approximately 70-135°C (160-275°F).
6. Start piston pin in piston and connecting rod. This may require a very light tap with a mallet.





7. Using Piston Pin Tool D81L-6135-A or equivalent, press piston pin through piston until piston pin bottoms on piston retainer ring.
8. Install a new piston pin retainer ring on other side of the piston bore.
9. After assembly, make sure connecting rod swings smoothly.
10. Install piston rings.
11. Install pistons and connecting rods.