Piston & Rod Assembly

TOOL REQUIRED
^ J 36660 Torque Angle Meter
^ J 5239 Connecting Rod Bolt Guide Set
^ J 8037 Piston Ring Compressor
^ J 24270 Ridge Reamer

REMOVAL
1. Remove the left (front) cylinder head.
2. Remove the right (rear) cylinder head.
3. Use the following procedure in order to remove the ring ridge, as necessary:
a. Turn the crankshaft until the piston is at the bottom of its stroke.
b. Place a cloth on top of the piston.





c. Use the Ridge Reamer in order to remove the piston ring ridge.
d. Turn the crankshaft so that the piston is at the top of its stroke.
e. Remove the cloth and cutting debris.
4. Remove the oil pan.
5. Remove the oil pump.
6. Remove the crankshaft oil deflector.
7. Turn the crankshaft until the piston is at bottom dead center.





8. Remove the connecting rod nuts and cap.

CAUTION: Install thread protector in order to avoid damage to the crankshaft journal.

9. Remove the connecting rod bearings.

CAUTION: Place matchmarks or numbers on the connecting rod and connecting rod caps. The connecting rod caps must be assembled to their original connecting rod.





10. Install the Connecting Rod Bolt Guide Set.
11. Remove the connecting rod and piston out of the top of the engine block.
12. Clean the cylinder bores with hot water and detergent or with a light honing.
13. Swab the bores with engine oil and a clean, dry cloth.

INSTALLATION
1. Coat the piston, the piston rings, the cylinder bore, and the bearing surfaces with engine oil.
2. Install the connecting rod thread protector.





3. Install the piston into its original bore using Connecting Rod Bolt Guide Set and the Piston Ring Compressor and lightly tapping the top of the piston with a wooden hammer handle.
4. When installing the piston and connecting rod, the stamped arrow on the piston must point to the front of the engine while the flange on the connecting rod must face toward the front of the piston on the left hand, and face toward the rear of the piston on the right hand.





5. Install the piston into it's original bore using Connecting Rod Bolt Guide Set and the Piston Ring Compressor and lightly tapping the top of the piston with a wooden hammer handle.
6. Hold the Piston Ring Compressor firmly against the engine block until all of the piston rings have entered the cylinder bore.
7. Remove the thread protector.
8. Raise and suitably support the vehicle.
9. Install the connecting rod bearings.
10. Install the connecting rod cap.
11. Install the connecting rod cap nuts. Tighten the nuts to 20 Nm (15 ft. lbs.). Use the Torque Angle Meter in order to rotate the nuts an additional 75 degrees.
12. Inspect the connecting rod for a binding by prying back and forth with a suitable tool. If necessary, loosen and retighten the connecting rod cap.





13. Measure the connecting rod side clearance.
14. Install the crankshaft oil deflector.
15. Install the oil pump.
16. Install the oil pan.
17. Install right (rear) the cylinder head.
18. Install left (front) the cylinder head.