Before you can pull the piston and connecting rod assemblies you have to take off the cylinder head, oil pan, and timing chain cover. Run a fingernail at about 1/4 inch down along the length of each cylinder to feel for any ridge at the top or at the limit of ring travel; if ridge by carbon or ordinary wear, it must be scrapped by a ridge reamer since it can cause a piston to break. Turn the engine so the
Crankshaft is in the upwards position, remove the balance shaft module, and the mounting bolts of the ladder frame to pull out the ladder frame from the engine block after eliminating the cylinder ridges. Before unbolting the main bearing caps and connecting rods check the connecting rod end play with feeler gauges; within the limit or not, it might require a new connecting rod. Identify the connecting rods and caps, turn the cap bolts gradually counterclockwise and remove the connecting rod cap and the bearing insert without allowing the insert to fall. Guide the connecting rod/piston assembly out out of the top of the engine with your bare hands or a wooden or plastic hammer handle If it is still difficult force the connecting rod/piston out and do the same for the other cylinders. Install and replace the connecting rod caps and bearing inserts in the proper connecting rods; best to leave the old inserts in the rods to prevent damaging them in the process. When fitting piston rings see that end gaps are correct and the side clearance for piston rings is also correct. Position all the pistons/connecting rods new rings, place the top ring into the 1 cylinder and with the feeler gauges, set the end gap. Begin by installing the oil control ring and thereafter the middle and the top rings but in the correct position. Cylinder bores must be cleaned and the top edge of each cylinder bore must be chamfered before installing the piston/connecting rod assemblies, and crankshaft must be in place. Take off the cap of the number one connecting rod, scrub the bearing surfaces, install the new upper bearing insert dry. Spacing of the piston ring gaps should now be at 90 degrees; lubricate the piston and rings and then use the piston ring compressor in the insertion of the piston into the cylinder. Inspect the connecting rod bearing oil clearance by fitting Plastigage , the surfaces should be clean and ought not to have any oil on them. If the clearance is not within the tolerance level, then bear in mind to recheck the bearing size and journal diameter. Remove any Plastigage material left on the bearing surfaces, lubricate the bearing surfaces with fresh grease or assembly lube and replace the connecting rod cap bolts and thread them to the recommended torque value. Do the same thing for the rest of the pistons and connecting rods paying attention to the cleanliness and assembly of each cylinder. Finally, the oil pump and flywheel are installed and the crankshaft is rotated to look for binding: the connecting rod endplay is also checked again, and compared to specifications.