Assembly Procedure
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 6V-6192 | Pliers | 1 |
| B | 7M-3978 | Ring Expander | 1 |
| C | 5P-8639 | Hydraulic Press (Connecting Rod Bearing) | 1 |
| 8F-0024 | Hose Assembly | 1 | |
| 1P-2375 | Connecting Coupler | 1 | |
| 1P-2376 | Connecting Coupler | 1 | |
| 5P-8651 | Spacer | 1 | |
| 5P-8649 | Adapter | 1 | |
| 5P-8650 | Bushing Adapter | 1 | |
| - | Hydraulic Pump | 1 | |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Install piston pin bearing (6) in connecting rod (4) , as follows:
Note: The old bearing is pushed out by Tool (C) as the new bearing is installed.
- Heat length (Y) of connecting rod (4) to a temperature of 175 to 260 °C (347 to 468 °F).
(Y) Maximum length for heating the connecting rod ... 85.0 mm (3.35 inch)
Show/hide table
Illustration 3 g00570892
Show/hide tableNOTICE The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.
- Use Tool (C) to remove the old bearing and install the new bearing at the same time. The adapter of Tool (C) should make full contact with the surfaces of the connecting rod.
Note: Orient the bearing joint within 5 degrees of either location (X) .
- Allow the connecting rod and the bearing to cool to room temperature.
- Heat length (Y) of connecting rod (4) to a temperature of 175 to 260 °C (347 to 468 °F).
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| Illustration 1 | g00786693 |
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| Illustration 2 | g00507526 |
- Use a pin boring machine to machine the bore of the piston pin bearing to the correct diameter.
Diameter of piston pin bore ... 50.830 ± .008 mm (2.0012 ± 0.0003 inch)
- Check the clearance between the ends of the piston rings (5) . Refer to Specifications, "Pistons And Rings" for additional information.
- Install the oil ring spring in the oil ring groove of the piston.
Note: The oil ring is installed over the spring with the oil ring end gap 180 degrees from the oil ring spring joint.
- Install the oil ring on the piston with Tool (B) .
 | |
| Illustration 4 | g00507525 |
- Use Tool (B) to install the intermediate piston ring with the side that has the identification "UP-2" toward the top of the piston.
- Use Tool (B) to install the top piston ring with the side that has the identification "UP-1" toward the top of the piston.
- Position the piston rings so the end gaps are 120 degrees from each other.
- Put piston crown (7) in position on piston skirt (8) .
- Put the piston in position on connecting rod (4) . Apply clean engine oil on piston pin (2) and install the piston pin. Install retainer rings (1) with Tool (A) . Ensure that the retainer rings are fully seated in the grooves of the piston.
- Install connecting rod bearings (3) in the connecting rod and the connecting rod cap.
Note: Ensure that the bearings are installed so that the bearing tabs fit into the notch in the connecting rod and the connecting rod cap.
End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".