Piston And Connecting Rod

REMOVAL 

1. Remove the oil pan and windage tray. Refer to PAN, OIL, REMOVAL AND INSTALLATION .
2. Temporarily place the front suspension crossmember in place without the steering gear and install the bolts to the body.

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3. Remove the tools (1) used to support the engine when removing and installing the front suspension crossmember.
4. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .

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   CAUTION:

   DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur.

   NOTE:

   Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

5. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.

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   NOTE:

   Special care is necessary when handling the joint separating upper and lower halves of the connecting rod. This fractured surface is sensitive and easily damaged, preventing proper reassembly of the cap to the rod. Avoid touching the fractured surfaces and contact with any other work surfaces. Under no circumstances should these surfaces be brushed. It is critical that the joint not be altered in any way during disassembly and assembly.

6. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before removing the pistons from the engine block. Be sure to keep the tops of pistons covered during this operation.  Pistons and connecting rods must be removed from the top of the engine block. When removing piston and connecting rod assemblies from the engine, rotate the crankshaft CW so that each connecting rod is centered in the cylinder bore.
7. Remove the connecting rod cap bolts (1a) and the connecting rod cap (1b) with lower half-bearing (1c). Discard the cap bolts (1a).

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   CAUTION:

   Care must be taken not to nick crankshaft journals, as engine damage may occur.

8. Remove the piston (1a) with connecting rod (1b) and half-bearing (1c) from the cylinder bore.
NOTE:

Upon disassembly of the connecting rod cap, small particles may be freed from inside of the joint. This is normal. Loose particles must not be trapped within the joint upon reassembly as they prevent proper assembly of the cap to the rod. To ensure loose particles are removed, concentrated air may be blown on the fracture surfaces.

9. Immediately after piston and connecting rod removal, reinstall the bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
10. Repeat the previous steps for each piston being removed.

INSTALLATION 

1. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore.

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2. The grooves (1a) on the piston crown must face towards the intake side, while the arrow (1b) indicates the timing side.

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3. The number engraved on the connecting rod (1d) identifies the cylinder number and must be the same as the one engraved on the connecting rod cap.

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   NOTE:

   Use care when stuffing piston into cylinder bore. Under no circumstances shall metal tools be used to tap or push piston into the cylinder bore.

4. Install the piston-connecting rod assembly complete with half-bearing using a suitable tool (1) to compress the piston rings and then fit the piston into the liner.

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   CAUTION:

   The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

   NOTE:

   Make sure connecting rod big end bore and bearing surfaces are free of any debris before installing bearings. Debris will affect bearing clearances.

5. Install the connecting rod cap (1) complete with half-bearing. Hand-tighten the NEW  bolts (2) evenly to ensure the cap does not bind.
6. Tighten the connecting rod cap bolts (2) to the proper specification Refer to SPECIFICATIONS  .
7. Repeat the previous steps for each piston being installed.
8. Install the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .

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9. Install the engine support tools (1).
10. Remove the bolts and remove the front suspension crossmember installed temporarily without the steering gear.
11. Install the windage tray and oil pan. Refer to PAN, OIL, REMOVAL AND INSTALLATION .