Orlando

Piston, Connecting Rod, and Bearing Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Remove intake camshaft. Refer to Inlet Camshaft Replacement .
2. Remove crankshaft balancer. Refer to Crankshaft Balancer Removal .



3. Set the crankshaft to TDC of combustion stroke of cylinder 1.
4. Remove and DISCARD the 4 connecting rod bearing cap retaining bolts (3) from the cylinder 2 and 3.
5. Remove the 2 bearing caps (2) from cylinder 2 and 3.
6. Remove the 2 lower big-end bearings (1) from cylinder 2 and 3.



7. Push the 2 pistons with the connecting rod (1) from cylinder 2 and 3 upwards.
8. Remove the 2 connecting rod upper bearings (2) from cylinder 2 and 3.
9. Turn the crankshaft through 180° and set the crankshaft to TDC of combustion stroke of cylinder 2.



10. Remove and DISCARD the 4 connecting rod bearing cap bolts (3) from the cylinder 1 and 4.
11. Remove the 2 big-end bearing caps (2) from cylinder 1 and 4.
12. Remove the 2 connecting rod lower bearings (1).



13. Push the 2 pistons with connecting rod (1) from cylinder 1 and 4 upwards.
14. Remove the 2 connecting rod upper bearings (2) from cylinder 1 and 4.

Note: The dot (1) on the piston skirt must point to the timing side to ensure that the notch (2) for the oil nozzle is at the correct position.

1. Displace the NEW piston ring joints 120° to each other.
2. Coat all pistons and cylinder bores and the EN-50425 compressor with engine oil.
3. Turn the crankshaft to TDC of combustion stroke of cylinder 2.



4. Use the EN-50425 compressor (1) as shown in the illustration above.

Note: When using the old pistons, old connecting rods and old big-end bearing caps, install them at their original positions.

5. Install the 2 NEW pistons with the NEW connecting rod (1) and the NEW connecting rod upper bearing shells (2) into cylinder 1 and 4.



6. Install the 2 big-end bearing caps (2) with the connecting rod lower bearing shells (1) to cylinder 1 and 4.

Note: Do not tighten the bearing cap retaining bolts (3).

7. Install 4 NEW big-end bearing shell bolts (3).

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

8. Tighten the 4 big-end bearing shell bolts (3) in 2 steps.

8.1.	First step tighten to 30 N·m (22 lb ft).

8.2.	Second step to an additional 70° , use the EN-470-B meter .

9. Turn crankshaft through 180° and set the crankshaft to TDC of combustion stroke of cylinder 1.




Note: When using the old pistons, old connecting rods and old big-end bearing caps, install them at their original positions.

10. Install 2 NEW pistons with NEW connecting rod (1) and NEW connecting rod upper bearing shells (2) into cylinder 2 and 3.



11. Install 2 NEW big-end bearing caps (2) with NEW connecting rod lower bearing shells (1) to cylinder 2 and 3.

Note: Do not tighten the bearing cap retaining bolts (3).

12. Install 4 NEW big-end bearing shell bolts (3).
13. Tighten the 4 big-end bearing shell bolts (3) in 2 steps.

13.1.

First step tighten to 30 N·m (22 lb ft).

13.2.

Second step to an additional 70° , use the EN-470-B meter .

14. Install crankshaft balancer. Refer to Crankshaft Balancer Installation .
15. Install intake camshaft. Refer to Inlet Camshaft Replacement .