Removal and Installation
CAUTION:Aluminum Components
Do not work on aluminum engine components until the engine is cold.
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.
REMOVAL
1. Remove cylinder heads as required.
2. Remove oil pan.
3. Inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA.
4. Turn crankshaft until connecting rod to be removed is at the bottom point of its travel, piston at bottom dead center (BDC).
NOTE: Mark position of connecting rod cap to connecting rod for aid in reassembly.
5. If more than one piston is being removed, identify the pistons, connecting rods and connecting rod caps for cylinder position.
6. Remove the connecting rod cap retaining bolts, connecting rod cap and lower connecting rod bearing. Keep connecting rod cap and lower connecting rod bearing together.
CAUTION: Care should be taken not to damage the connecting rod and cap joint face surfaces or possible engine damage may occur.
7. Using Connecting Rod Guide Tool T94P-6136-AH installed into the connecting rod bolt holes, push the piston, connecting rod and upper connecting rod bearing through the top of the cylinder bore. Use care to prevent damage to the crankshaft bearing journals and cylinder bore surfaces. Keep upper connecting rod bearing and connecting rod together.
CAUTION: Connecting rod bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused.
8. Connecting rod bolts are retained in the bolt hole with a light press fit. The bolts have been torqued to yield at least twice and must be discarded. Using a hammer and punch, drive bolts from bolt holes.
9. Using a new connecting rod bolt, attach connecting rod cap and lower connecting rod bearing to connecting rod and upper connecting rod bearing to prevent mixing parts and damaging the connecting rod joint face surfaces.
10. Repeat procedure until all necessary pistons and connecting rods are removed.
INSTALLATION
NOTE: If required, deglaze the cylinder walls using a suitable spring type tool. Clean the cylinder walls with a detergent and water solution with the engine upside down to prevent contamination of the crankshaft and bearings.
1. If disassembled, assemble pistons onto connecting rods. If being replaced, assemble new piston rings onto pistons.
NOTE: The connecting rod bearing tangs should align with notch in connecting rod and cap.
2. Install connecting rod bearings into connecting rods and connecting rod caps.
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:
Lubricate pistons, piston rings, connecting rods and connecting rod bearings with Engine Assembly Lubricant prior to installation.
Install with arrow on piston to front of engine.
3. Turn crankshaft until crankshaft throw is at bottom of stroke. Install correctly numbered piston and connecting rod with Piston Ring Compressor D81L-6002-C or equivalent and Connecting Rod Guide Tool T94P-6136-AH.
CAUTION:
Cleaning Components
It is imperative that the connecting rod cap be cleaned and properly aligned to the connecting rod. The connecting rod and connecting rod cap bearing tangs/slots must be located on same side of connecting rod.
4. Install connecting rod cap and connecting rod bearing onto connecting rod. Alternately tighten new torque-to-yield connecting rod bolts in several passes to 40-45 Nm (30-33 ft. lbs.). Rotate connecting rod bolts 90-120°.
5. After installation of each piston and connecting rod, rotate crankshaft to verify smooth operation.
NOTE: Position crankshaft so that piston, pin and rings are below the cylinder block surface to prevent damage to the piston, pin and ring.
6. Check connecting rod side clearance using Dial Indicator with Bracketry. Side clearance should be 0.10-0.25 mm (0.004-0.010 inch).
7. If connecting rod side clearance is greater than maximum service limit, replace connecting rod and/or crankshaft.