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| Illustration 1 | g01726279 |
(1) Bore in connecting rod for piston pin bearing ... 140.000 ± 0.015 mm (5.5118 ± 0.0006 inch)
(2) Bore in piston pin bearing for new piston pin ... 130.104 ± 0.01 mm (5.1222 ± 0.0004 inch)
Diameter of new piston pin ... 129.944 ± 0.006 mm (5.1159 ± 0.0002 inch)
Note: Assemble the piston pin retainer with the surface of the piston pin retainer that is marked facing toward the piston pin. When the piston crown is in the 12 o'clock position, the gap in the piston pin retainer must be in the 6 o'clock position.
(3) Distance between center of bearings ... 600.00 mm (23.622 inch)
(4) Bore in connecting rod for bearing ... 244.00 ± 0.015 mm (9.6063 ± 0.0006 inch)
(5) Bore in bearing for crankshaft ... 235.169 to 235.231 mm (9.2586 to 9.2610 inch)
Clearance between bearing and crankshaft ... 0.169 to 0.279 mm (0.0067 to 0.0110 inch)
(6) Connecting rod bolts
Replace the connecting rod bolts if the following condition occurs:
- The length of the bolts exceeds 246.2 mm (9.7 inch).
(7) Thickness of connecting rod ... 103.5 mm (4.1 inch)
Procedure for Locating the Connecting Rod Bearings
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| Illustration 2 | g01726554 |
- Liberally coat the inner diameter of the connecting rod bearing and the outer diameter of the crankshaft journal with clean engine oil. Use clips (2) to assemble both halves of the bearing at the correct position on the journal. Make sure that the clips are secure.
Note: The clips (2) for the bearing may not be reused. Ensure that the bearing is assembled with new clips and that the clips are secure in the bearing. The clip must not be proud to the back of the bearing.
- Remove the towels from the connecting rod. Ensure that debris or residue from the towels cannot contaminate the engine.
- Use a cloth that is dampened with clean engine oil to apply a light coat of oil onto the outer diameter of the connecting rod bearing.
- Make sure that the connecting rod is aligned with the crankshaft. Slowly lower the connecting rod onto the connecting rod bearing.
- Rotate the connecting rod bearing until the dowel in the bearing (A) is inserted into the slot in connecting rod (1) . The bearing must be moved away from the back of the slot in the connecting rod in order to allow a clearance of 0.5 mm (0.02 inch) between the dowel and the rear of the slot. Once the connecting rod is in place on the crankshaft bearing, the crankshaft will need to be rotated in order to allow the connecting rod cap to be assembled to the connecting rod. The gap between the slot in the connecting rod and the locating dowel must be verified for proper clearance of 0.5 mm (0.02 inch).
Note: Always control the length of the connecting rod bolts. The length of a new bolt is 245 ± 0.1 mm (9.6 ± 0.004 inch). This distance is measured from the bottom of the seat to the end of the bolt. Do not use a bolt if the length of the bolt exceeds 246.2 mm (9.7 inch). Inspect the entire bolt for damage. Run a nut along the entire length of the threads in order to verify that the thread is acceptable.
| NOTICE |
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It is very important that the dowel in the connecting rod bearing is inserted into the slot in the connecting rod. If the dowel is not inserted into the slot, damage to the engine will occur. |
- Coat the contact surfaces of the connecting rod bolts with 6V-4876 Lubricant or with 186-1531 Lubricant .
- Install Tool (B) into two opposite holes in the connecting rod. Make sure that the same serial numbers are on the connecting rod and the connecting rod cap. Make sure that the numbers align and place connecting rod cap (3) onto Tool (B) . Move the rod cap toward the connecting rod. Install two of the bolts and the retainer plates. Remove Tool (B) . Install the other two bolts.
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| Illustration 3 | g01726617 |
Tightening Procedure for the Connecting Rod Bolts
Before you fully tighten the bolts, make sure that the bolt heads are centered in the counterbore of the retainer plates. Hand tighten bolts.
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| Illustration 4 | g00897470 |
Note: In Illustration 4, the bolts (2) and (4) are at the rod thrust side and the bolts (1) and (3) are to the crankshaft side of the rod.
Note: Special care must be taken when bolts (1) and (4) are tightened in order to make sure that the retainer plates do not move.
Note: Always use a master to calibrate torque tools before use and after use in order to ensure accuracy.
Always complete the following torque sequence on the connecting rod that has just been installed prior to any further rotation of the crankshaft. Rotation without completing the torque sequence can result in bearing rotation and subsequent bearing damage.
- Tighten the following bolts in this sequence to a torque of 60 ± 10 N·m (44 ± 7.4 lb ft): (1) , (4) , (2) , (3) .
- Tighten the following bolts in this sequence to a torque of 300 ± 20 N·m (222 ± 14.8 lb ft): (1) , (4) , (2) , (3) .
- Tighten the following bolts in this sequence to a torque of 600 ± 30 N·m (440 ± 22 lb ft): (1) , (4) , (2) , (3) .
- Tighten all the bolts again in the same sequence that was instructed in Step 3.
Note: This sequence gives proper alignment to the cap and the rod and closes the joint properly. This sequence also puts the proper crush on the bearing.
- Loosen bolt (1) . Then tighten bolt (1) to 15 ± 3 N·m (11 ± 2 lb ft). Then turn bolt (1) for an additional 150 ± 5 degrees.
- Loosen bolt (4) . Then tighten bolt (4) to 15 ± 3 N·m (11 ± 2 lb ft). Then turn bolt (4) for an additional 150 ± 5 degrees.
Note: There is a special socket that can be used as a reference. The socket is used as a reference for the additional turning of the bolt.
- Loosen bolt (2) . Then tighten bolt (2) to 15 ± 3 N·m (11 ± 2 lb ft). Then turn bolt (2) for an additional 150 ± 5 degrees.
- Loosen bolt (3) . Then tighten bolt (3) to 15 ± 3 N·m (11 ± 2 lb ft). Then turn bolt (3) for an additional 150 ± 5 degrees.
- Verify that all bolts have been torqued to a minimum of 600 N·m (442.5 lb ft) in order to verify the tension of the bolt.
- Install the retainer plates (5) for the bolts. Then retain the locking plates (6) by using specific 6.35 mm (0.25 inch) bolts (7) . After the 6.35 mm (0.25 inch) bolts (7) are properly tightened to 12 ± 3 N·m (9 ± 2 lb ft), bend the locking tabs (6) into position on the retaining plates.
Note: No additional turning of the bolts is allowed. If any motion is detected, remove all four bolts and return to Step 1.
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| Illustration 5 | g01726653 |