Tools Required

1. Rotate the crankshaft so the connecting rod journal for the piston being installed is at Bottom Dead Center.
2. Lubricate the cylinder wall with engine oil.
3. Lubricate the piston and rings with engine oil.
4. Stagger the ring end gaps 90 degrees apart.
5. Use EN-48260 to compress the rings.
6. Install the connecting rod bearings into the connecting rods and caps (1).



7. Lubricate the connecting rod bearing contact surfaces with engine oil.
8. Install the J 41556 into the connecting rod.




Important: The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and connecting rod assembly into the proper cylinder bore. The piston alignment mark MUST face the front of the engine block (1) or the flat casting boss (2).

9. Install the connecting rod and piston into the proper cylinder bore.




Important: The oil hole, in the connecting rod, should be facing the exhaust side of the block.

10. Make sure to install the connecting rod facing the right direction.



11. Hold EN-48260 firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.



12. Guide the connecting rod end onto the crankshaft journal.

Use J 41556 to pull the connecting rod into place.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

13. Install the connecting rod bearing, cap, and bolts.

Tighten

1. Tighten the connecting rod bearing cap bolts on the first pass to 25 N·m (18 lb ft).
2. Use J 45059 to tighten the connecting rod bearing cap bolts on the second pass an additional 110 degrees.



14. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankshaft.
15. Measure the connecting rod side clearance using a feeler gauge. Connecting rod side clearance should be between 0.05-0.35 mm (0.0019-0.0137 in).