Assembly Procedure
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 6V-6192 | Pliers | 1 |
| B | 7B-7974 | Piston Ring Expander Gp | 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 | |
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.
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Raise heat on connecting rod (6) along Length (Y) .
(Y) Maximum Length for heating the connecting rod ... 95 mm (3.7 inch)
 | |
| Illustration 1 | g01017742 |
 | |
| Illustration 2 | g01018268 |
| NOTICE |
|---|
The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch. |
- Allow the connecting rod and the bearing to cool to room temperature.
- Use Tooling (C) to remove the old bearing and install new bearing (7) at the same time. The adapter of Tooling (C) should make full contact with the surfaces of connecting rod (6) .
Note: Orient the bearing joint within ± 5 degrees of either Location (X) .
- Use a pin boring machine to machine the bore of bearing (7) to the correct diameter.
Diameter of bearing bore ... 60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)
- Position the spring for the oil control piston ring in the oil ring groove in the piston body assembly.
 | |
| Illustration 3 | g01056145 |
- Position oil control piston ring (3) over the spring. Position the oil control piston ring so that the gap is 180 degrees from the joint in the spring. Install the oil control piston ring on the piston with Tooling (B) .
- Use Tooling (B) to install intermediate piston ring (2) with the side that has the identification "UP-2" toward the top of the piston.
- Use Tooling (B) to install top piston ring (1) with the side that has the identification "UP-1" toward the top of the piston.
- Position piston rings (1) , (2) , and (3) so the gaps are 120 degrees from each other.
- Check the clearance between the ends of piston rings (1) , (2) , and (3) . Refer to Specifications, "Pistons And Rings".
- Position piston body assembly (4) on connecting rod (6) . Apply clean engine oil to connecting rod pin (8) and install the connecting rod pin. Install pin retainer (5) with Tooling (A) .
- Install upper connecting rod bearing (9) in connecting rod (6) .
Note: Ensure that the bearing locking tab is located in the notch of the connecting rod.
- Install lower connecting rod bearing (10) in connecting rod bearing cap (11) .
Note: Ensure that the bearing locking tab is located in the notch of the connecting rod bearing cap.
- Ensure that the dowels are installed in the connecting rod bearing cap.
End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".