Usage:
start by:
a) remove cylinder head assembly
b) remove turbocharger lubrication valve
1. Remove breather assembly (1).
2. Remove oil lines (4).
3. Remove water line (2) and inspection covers (3).
4. Remove the carbon ridge from top of cylinder liner.
5. Turn crankshaft and move connecting rod into position with tooling (A).
6. Remove the nuts that hold on connecting rod cap.
7. Remove cap (6) and bolts (5) from connecting rod.
8. Turn crankshaft until piston is at top of stroke. Turn crankshaft away from connecting rod and remove upper half of bearing.
9. Push piston up until piston rings are out of cylinder liner.
10. Remove piston (7) and connecting rod from cylinder. Weight of piston and connecting rod is 40 lb. (18 kg).
11. Do Steps 4 through 10 for remainder of pistons.
Install Pistons
1. Put clean oil on cylinder liner, piston and piston rings.
NOTE: Put ring gaps in place 120° from each other.
2. Put compressor (B) on top of cylinder liner. Install piston (1) through compressor in cylinder liner using the liner as a guide. Turn piston until "V" mark (2) on piston is in alignment with "V" mark (3) on cylinder block.
3. Carefully push piston into cylinder making sure each ring takes its place in the piston groove.
4. Install the upper half of bearing in connecting rod.
5. Put clean oil on upper half of bearing and crankshaft journal. Turn crankshaft into place in the connecting rod. Install the bolts in connecting rod.
6. Put clean oil on lower half of bearing and install the cap and nuts.
| NOTICE |
|---|
Notch in cap must be installed on same side as notch in connecting rod. Make sure head of bolts are in correct position. |
7. Tighten nuts to 75 ± 5 lb. ft. (100 ± 7 N·m). Put a mark across bolt and nut. Tighten nuts 60° from marks on bolts.
8. Do Steps 1 through 7 for remainder of pistons.
9. Install inspection covers (6).
10. Install water line (5) and oil lines (7).
11. Install breather assembly (4).
end by:
a) install turbocharger lubrication valve
b) install cylinder head assembly
Remove Pistons
start by:
a) remove cylinder head assembly
b) remove oil pump
NOTE: The rear three connecting rod caps are removed through the side of the cylinder block. The front three connecting rod caps are removed from under the front of the engine.
1. Remove bolts (2) that hold the rear cover in position.
2. Remove cover (1).
3. Remove the carbon from the inside at the top of the cylinder liner.
4. Remove bolts and nuts (3) from the connecting rod caps.
5. Turn the crankshaft until the piston to be removed is at top center position.
6. Push the connecting rod and piston up until the piston rings are out of the cylinder liner.
7. Remove piston (4) and the connecting rod from the cylinder liner. Weight of the piston is approximately 40 lb. (18 kg).
NOTE: 7N5037 Piston Group is a replacement for the 6N6642 Piston Group and 3S5502 Piston Assembly. See Page 113 for installation.