Removal and Replacement
OVERVIEW1. Remove the following components:
- Intake manifold/plenum
- Cylinder head covers
- Timing belt
- Cylinder heads
- Oil pan
Fig. 77
2. Identify and mark pistons. The pistons are not interchangeable from bank to bank (Fig. 77).
2. Pistons with the letter R and arrow toward the front of engine are to be installed in cylinders 1-3-5. Pistons with the letter L and arrow toward the front of engine are to be installed in cylinders 2-4-6.
Fig. 78
3. Mark connecting rod and cap with cylinder number (Fig. 78).
Fig. 79
4. Remove piston rings (Fig. 79).
FITTING PISTONS
Fig. 80
Measure approximately 2 mm (0.080 inch) above the bottom of the piston skirt and across the thrust face (Fig. 80).
FITTING PISTON RINGS
Fig. 81
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 16 mm (0.63 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 81).
Fig. 82
2. Check piston ring to groove clearance (Fig. 82). Refer to Engine; Specifications.
PISTON RINGS-INSTALLATION
Fig. 83
1. The No. 1 and No. 2 piston rings have a different cross section. Install rings with manufacturers mark and size mark facing up, to the top of the piston (Fig 83)
CAUTION: Install piston rings in the following order:
a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
Fig. 84
2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander (Fig. 84).
3. Install upper side rail first and then the lower side rail.
Fig. 85
4. Using a piston ring expander, install No. 2 piston ring and then No. 1 piston ring (Fig. 85).
Fig. 86
5. Position piston ring end gaps as shown in (Fig. 86).
6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction.
Fig. 87
7. Connecting rod front mark 72 must always face forward, toward timing belt end. (Fig. 87)
8. Install the piston and connecting rod assembly into there respective bore from the cylinder block top.
CAUTION: Piston assemblies are not to be interchanged from bank to bank.
Fig. 88
9. Check alignment marks made during disassembly and that bearing position notches new or used are on the same side as shown in (Fig. 88).
10. Install the following components:
- Oil pan
- Cylinder heads
- Timing belt
- Cylinder head covers
- Intake manifold/plenum