Replacement, Engine Overhaul
^ Tools Required- J 24270 Ridge Reamer
- J 5239 Connecting Rod Guide Tool
- Or Equivalents
REMOVAL
NOTE: Do not remove the excessive material from the cylinder bore. Excessive removal of material may require cylinder boring to the next oversize.
1. Remove the cylinder bore ridge as necessary.
(1) Rotate the crankshaft until the piston is at before top dead center.
(2) Place a cloth on top of the piston.
(3) Perform the cutting operation with a ridge reamer. Refer to the manufacturers instructions.
(4) Remove the ridge reamer.
(5) Rotate the crankshaft until the piston is at TDC.
(6) Remove the cloth and the cuttings.
(7) Repeat the procedure for each piston.
NOTE:
^ Place the matchmarks or numbers on the connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods. Remove the connecting rod nuts.
^ If reusing, keep the bearings with their original connecting rod and connecting rod cap.
2. Wipe the oil from the bearings and the crankpins.
3. Remove the connecting rod cap and the bearing.
INSTALLATION
^ Tools Required
- J 5239 Connecting Rod Guide Tool
- J 8037 Piston Ring Compressor
- Or Equivalents
NOTE: In order to determine the correct replacement bearing size, the bearing clearance must be measured accurately. Either the micrometer or plastic gauge method may be used, however, the micrometer method gives more reliable results and is preferred.
CAUTION: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.
1. Install connecting rod bearings to the connecting rods and connecting rod caps.
2. Lubricate the cylinder walls lightly with engine oil.
3. With the connecting rod cap removed, Install the connecting rod guide tool onto the connecting rod bolts.
4. Align the piston ring end gaps.
5. Lubricate the piston and the rings with engine oil.
6. Without disturbing the ring end gap location, Install the piston ring compressor over the piston and the ring assembly.
7. Compress the piston rings.
8. Ensure that the dimple faces the front of the block.
NOTE: Each connecting rod and bearing cap should be marked for proper location and orientation. Cylinder 1, 3, and 7 are the right bank and 2, 4, 6, and 8 are the left bank (when viewed from the front of the engine). The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new connecting rod bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.
9. Install the piston and the connecting rod to the proper bore.
10. Use a hammer handle to lightly tap the piston down into the cylinder bore.
11. While tapping the piston into the bore, guide the connecting rod into position on the crankpin, using the connecting rod guide tool.
The connecting rod bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, the new upper and the lower bearings will be required. The service bearings are available in the standard size and an undersize.
^ 0.001 inch
^ 0.002 inch
^ 0.010 inch
^ 0.020 inch
The selective fitting of the connecting rod bearings are necessary in production in order to obtain close tolerances. For this reason, you may use one-half of a standard connecting rod bearing with one-half of a undersize connecting rod bearing.
4. Remove the connecting rod and the piston out of the top of the engine block using the connecting rod guide tool.
5. Remove the remaining piston and the connecting rod assemblies.