Assembly Procedure
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 4C-3601 | Piston Ring Expander | 1 |
| B | 1P-1861 | Retaining Ring Pliers | 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 | |
| 9U-6600 | Hydraulic Pump | 1 | |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The components must be reassembled together. The components must be installed in the original location in the engine. Do not interchange any of the components.
Note: Fractured connecting rods must be handled with care. Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.
- Use the following procedure to remove bearing (8) and install new bearing in the connecting rod.
- Heat Length (Y) of connecting rod (10) to a temperature of 175 to 260 °C (347 to 500 °F).
(Y) Maximum Length for heating the connecting rod ... 83 mm (3.3 inch)
Show/hide tableNOTICE The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.
- Orient the bearing joint within ± 5 degrees of either Location (X) . Use Tooling (C) to remove the old bearing and install the new bearing (8) at the same time.
- Allow the connecting rod and the bearing to cool to room temperature.
- Heat Length (Y) of connecting rod (10) to a temperature of 175 to 260 °C (347 to 500 °F).
 | |
| Illustration 1 | g01144899 |
Note: Use Tooling (C) to remove the old bearing and install the new bearing (8) at the same time. The adapter of Tooling (C) should make full contact with the surfaces of connecting rod (10) . Replace bearing (8) by pressing a new bearing into the connecting rod.
- Use a pin boring machine to machine the bore of bearing (8) to the correct diameter.
Diameter of bearing bore ... 46.035 ± 0.008 mm (1.8124 ± 0.0003 inch)
- The piston crown (1) must be replaced if the piston crown is worn or damaged. Bearings (6) are nonserviceable.
 | |
| Illustration 2 | g01144952 |
- Position piston crown (1) and piston skirt (7) on connecting rod (10) . Apply clean engine oil to connecting rod pin (9) and bearing (8) . Install connecting rod pin (9) . Install pin retainers (5) with Tooling (B) . Make sure that the retaining rings are fully seated in the grooves of the piston skirt.
- Use Tooling (A) to install oil control ring (4) on the piston.
Note: Position the oil control ring so that the gap is 180 degrees from the joint in the spring.
- Use Tooling (A) to install intermediate piston ring (3) with the side marked "UP-2" toward the top of the piston.
- Use Tooling (A) to install top piston ring (2) with the side marked "UP-1" toward the top of the piston.
- Install the upper half of connecting rod bearing (12) in connecting rod (10) .
- Install the lower half of connecting rod bearing (13) in connecting rod cap (11) .
- Install connecting rod cap (11) on the connecting rod. Install bolts (14) finger tight in order to protect fractured faces of the connecting rod cap and the connecting rod.
Note: Ensure that the number on the connecting rod cap matches the number on the connecting rod, and that the numbers are on the same side.
End By: Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".