Usage:
start by:
a) remove pistons
1. Remove the rings from the piston with tool (A).
2. Remove the bearings from the connecting rod and connecting rod cap.
3. Remove snap rings (2), pin (1) and connecting rod (3) from the piston.
4. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295 for more information of removal and installation of piston pin bearings.
5. Heat the connecting rod to a temperature of 350 to 400°F (176 to 204°C). Put 5P8654 Spacer (11) in the base plate. Put the connecting rod on the base plate of tooling (B).
6. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B). Install pin (7) in the center of the bore for the connecting rod bearings.
7. Install 5P8653 Adapter (9). Put the hole in the adapter in alignment with the hole in the base plate of tooling (B).
8. Install clamp bar (10) and clamp pin (6).
9. Install new piston pin bearing (5) on adapter (9).
NOTE: The old bearing is pushed out by tooling (B) as the new bearing is installed.
10. Put 5P8645 Adapter (8) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (9) and the base plate of tooling (B).
11. Put pusher (4) on adapter (8).
12. Use tooling (B) to push the new piston pin bearing into the connecting rod until adapter (8) of tooling (B) makes full contact with the connecting rod surface.
13. Remove the connecting rod and the old piston pin bearing from tooling (B).
14. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension is 1.5010 ± .0003 in. (38.125 ± 0.008 mm).
Assemble Pistons (Direct Injection)
1. Install connecting rod (3) in the piston with the bearing tab groove (slot) on the opposite side as the hole (crater) in top of the piston.
2. Install piston pin (2) and snap ring (1).
3. When old pistons are to be used, clean the piston grooves with tool (A).
4. Install the spring for the oil ring. Install the oil ring with tool (B). The gap in the ring must be approximately 180° from the oil ring spring connections.
5. Install the compression ring with tool (B). The side of the ring that has the identification "TOP" must be toward the top of the piston. The gaps in the rings must be approximately 120° apart.
NOTE: Compression rings that do not have identification must be installed with the edge that has the bevel toward the top of the piston.
6. Install connecting rod bearings.
end by:
a) install pistons