Pistons and Connecting Rods – Remove and Install


Removal Procedure

Remove:
- the cylinder head.
- the engine oil pump.
- the piston cooling jets. Use Tooling to rotate the crankshaft until the crank pin is at the bottom center position. Use Tooling to remove the carbon ridge from the top inside surface of the cylinder bore.


The connecting rod and the connecting rod cap should have an etched number (X) on the side. The number on the connecting rod and the connecting rod cap must match. Ensure that the connecting rod (1) and the connecting rod cap (2) are marked for the correct location. If necessary, make a temporary mark on the connecting rod and the connecting rod cap in order to identify the cylinder number. Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture.
- the two setscrews (3) and the connecting rod cap (2) from the connecting rod (1).


Carefully push the piston (4) and the connecting rod out of the cylinder bore. Lift the piston (4) out of the top of the cylinder block. Do not push on the fracture split surfaces of the connecting rod as damage may result.
Repeat Steps for the remaining pistons and connecting rods. Fracture split connecting rods should not be left without the connecting rod caps installed. Temporarily install the connecting rod cap (2) and the setscrews (3) to the connecting rod (1) when the assembly is out of the engine. Ensure that the etched number on connecting rod cap matches the etched number on connecting rod . Ensure the correct orientation of the connecting rod cap . The locating tab for the upper bearing shell and the lower bearing shell should be on the same side. Tighten the setscrews (3) to a torque of 20 N·m (14 lb ft).

Installation Procedure

If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components.
Apply clean engine oil to the cylinder bore, to the piston rings, to the outer surface of the piston and to the bearing shells for the connecting rod. Install the bearing shells for the connecting rods dry when clearance checks are performed. Ensure that the piston and the connecting rod assembly is installed in the correct cylinder. Use Tooling to rotate the crankshaft until the crankshaft pin is at the bottom center position. Lubricate the crankshaft pin with clean engine oil.


Install Tooling onto the piston (4). Ensure that Tooling is installed correctly and that the piston (4) can easily slide from the tool. The arrow on the top of the piston must be toward the front of the engine. The locating tab for the bearing shell of the connecting rod must be on the same side of the engine as the piston cooling jet.
Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin. Do not damage the finished surface of the crankshaft pin.


Install:
- the connecting rod cap (2) onto the connecting rod (1). Ensure that the etched number (X) on connecting rod cap (2) matches the etched number (X) on connecting rod (1). Ensure the correct orientation of the connecting rod cap (2). The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.
- two new setscrews (3) to the connecting rod (1). Tighten the setscrews evenly to a torque of 18 N·m (13 lb ft). Do not reuse the old setscrews in order to secure the connecting rod cap. Tighten the setscrews evenly to a torque of 70 N·m (52 lb ft). Turn the setscrews for an additional 120 degrees. Use Tooling to achieve the correct final torque. Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. Repeat Steps to install the remaining pistons and connecting rods. Check the height of the pistons above the top face of the cylinder block.
- the piston cooling jets.
- the engine oil pump.
- the cylinder head.

Piston Cooling Jets

Removal Procedure

Remove the engine oil pump. If the crankshaft is installed, use Tooling to rotate the crankshaft in order to gain access to the piston cooling jet.


Remove the setscrew (1) and the piston cooling jet (2) from the cylinder block. Repeat steps for the remaining piston cooling jets.

Installation Procedure

Clean the piston cooling jets and inspect the piston cooling jets for damage. Ensure that the valve is free to move within each piston cooling jet. Replace any damaged piston cooling jets. If the crankshaft is installed, use Tooling to rotate the crankshaft in order to access the mounting flange for the piston cooling jet. Position the piston cooling jet (2) in the cylinder block. Install the setscrew (1). Tighten the setscrew (1) to a torque of 9 N·m (80 lb in). Repeat steps for the remaining piston cooling jets. Install the engine oil pump.