Replacement
TOOL REQUIRED^ J 36660 Torque Angle Meter
^ J 41507 Connecting Rod Assembly Guide
REMOVAL
1. Remove the cylinder head.
2. Remove the oil pan.
3. Mark the piston with the number of the cylinder from which it is being removed.
4. Mark the connecting rod and the rod cap so that they can be assembled correctly.
5. Turn the crankshaft to Bottom Dead Center (BDC).
6. Clean the carbon from the top end of the cylinder.
7. Remove the connecting rod bolts.
8. Remove the connecting rod cap and lower connecting rod bearing.
CAUTION: If there is a pronounced ridge at the top of the piston travel, the ridge must be removed with a ridge reamer before the piston and connecting rod assembly are removed. Applying force may break the piston rings or damage the piston.
9. Install Connecting Rod Assembly Guide on the connecting rod.
WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.
CAUTION: Do not use force when removing the connecting rod and piston. Avoid breaking the piston rings and damaging the piston.
10. Remove the piston, connecting rod and upper connecting rod bearing. Push out the piston, connecting rod and upper connecting rod bearing with a suitable tool.
INSTALLATION
1. Install the piston rings to the piston. Stagger the ring gaps to provide an effective compression seal.
2. Turn the crankshaft to BDC.
3. Lubricate the cylinder with oil.
4. Install the upper connecting rod bearing.
5. Install Connecting Rod Assembly Guide on the connecting rod.
6. Align the piston and the connecting rod with the arrow toward the front of the engine.
CAUTION: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.
7. Install the piston and connecting rod using a ring compressor.
CAUTION: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etch the bearing surface. Upper and lower inserts may be different. Do not obstruct any oil passages. Ensure that the bearing cap bolt holes and the cap mating surfaces are clean and dry. The inserts will project slightly when put into place. Ensure that they project an equal distance on both sides. Ensure that the insert-tangs are engaged.
8. Install the bearing inserts to a clean and dry connecting rod and cap.
9. Measure the rod bearing clearance. If the readings are within limits, select a suitable set of inserts. If the readings are unsatisfactory and available inserts will not correct the clearance, replace the crankshaft.
10. Lubricate the bearing surfaces and the crankshaft journal surfaces with clean engine oil.
11. Remove Connecting Rod Assembly Guide.
CAUTION: Carefully tap the bearing cap into place. Do not pull the cap down with the cap bolts.
12. Install the connecting rod cap and lower connecting rod bearing.
13. Install the connecting rod cap bolts. Tighten the bolts to 27 Nm (20 ft. lbs.). Use Torque Angle Meter in order to rotate the bolts an additional 50°.
14. Pry the connecting rod back and forth with a suitable tool and check for binding. If necessary, loosen and retighten the bearing cap.
15. Measure the connecting rod side clearance.
16. Install the oil pan.
17. Install the cylinder head.