Usage:
Start By:
a. remove cylinder head
b. remove oil pan
1. Remove the ring of carbon from the inner surface of the cylinder liners.
2. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1) from the two connecting rods.
3. Put rubber hose or tape over the threads of the connecting rod bolts. This will prevent damage to the crankshaft when the pistons are removed.
| NOTICE |
|---|
Do not let the connecting rods hit crankshaft when the pistons are removed or installed. |
4. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder liner. Remove the two pistons (2) and connecting rods from the engine.
5. Keep each connecting rod cap with its respective connecting rod and piston. Put identification on each connecting rod as to its location in the engine.
6. Do Steps 2 through 5 for the removal of the other pistons.
Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.
2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.
3. Move the piston rings on the piston until the ring openings are approximately 90° apart.
| NOTICE |
|---|
Do not use an impact wrench to tighten the rod bolts the additional 90°. |
4. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.
5. Push the piston into position while the connecting rod is put into position over the crankshaft.
6. Put clean engine oil on the bearings. Put 2P2506 Thread Lubricant on the bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
| NOTICE |
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When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod. |
7. Follow Steps 1 through 6 for the installation of the other pistons.
End By:
a. install cylinder head
a. install oil pump
Disassemble Pistons
Start By:
a. remove pistons
1. Remove the rings from the pistons with tool (A).
2. Remove retaining ring (3), piston pin (1) and connecting rod (2) from the piston.
3. Clean the piston ring grooves on the old piston with an acceptable ring groove tool.
4. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295, for more information about removal and installation of piston pin bearings.
NOTE: Be sure to remove the bearings from the crankshaft end of connecting rod.
5. Heat the connecting rod in an oven to a temperature of 177° - 260°C (350° - 500°F). Never use a direct flame to heat a connecting rod.
6. Put 6V3029 Spacer (11) in the base plate. Put the connecting rod on the base plate of tooling (B).
7. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B). Install pin (6) in the center of the bore for the connecting rod bearing.
8. Install 6V2049 Adapter (9). Put the hole in the adapter in alignment with the hole in the base plate of tooling (B).
9. Install clamp bar (10) and clamp pin (7).
NOTE: The old bearing is pushed out by tooling (B) as the new bearing is installed.
10. Put 5P8645 Pusher 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 (5) 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 43.210 ± 0.0076 mm (1.7012 ± .0003 in.). The maximum permissible clearance between the bearing and piston pin (worn) must not be more than 0.08 mm (.003 in.).
Assemble Pistons
1. Install the connecting rod (2) in the piston with the bearing tab groove (slot) (12) on the same side as the cutout (depression) (13) on the head of the piston.
2. Install piston pin (1) and retaining rings (3) in piston.
3. When old pistons are to be used, clean the piston grooves with an acceptable piston groove cleaning tool.
4. Install the spring for the oil ring. Install the oil ring with tool (A). The gap in the ring must be approximately 180° from the ring spring connections.
5. The two compression rings have marks "UP-1" and "UP-2". The rings must be installed with these marks toward the top of the piston with "UP-1" as the top ring. After installation of all three piston rings, put piston rings in position so gaps in rings are 120° apart.
NOTE: Compression rings that do not have identification can be installed either way.
6. To check the clearance between the piston ring grooves and rings, see SPECIFICATIONS.
7. See SPECIFICATIONS to check the clearance between the ends of the piston rings (end gap).
End By:
a. install pistons