Connecting Rod: Service and Repair

REMOVAL






NOTE: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly.

1. Remove the connecting rod cap nuts, then remove the caps and the big end lower bearing.
2. Push each piston connecting rod assembly toward the top of the cylinder and out of the block.






3. Use the piston pin fixture tool No. 09234-33001, or equivalent, to disassemble and reassemble the piston and connecting rod.
4. Place the proper insert in the fork of the tool.
- Insert the position between the connecting rod and the piston.






5. Insert the proper removal tool through the hole in the arch of the tool.

NOTE: Center the piston, rod and pin assembly with the removal arbor.

INSTALLATION






1. Install proper pin guide through piston and into connecting rod.
- Hand tap pin guide into piston for proper retention.
- Drop piston pin into the other side of the piston.

NOTE:
- The pin guide centers the connecting rod in the piston.
- When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the tool.
- If too small a pin guide is used, the piston assembly will not be located centrally in the tool, and damage may occur to the fork and/or insert of the tool.






2. Install piston assembly onto fork assembly of tool.
- Tool will support connecting rod at the piston pin, be sure to slide the piston assembly onto the fork until the pin guide contacts the fork insert.
3. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alpha-numeric setting from the application chart is obtained.
- Turn knurled nut to lock numbered sleeve on shaft.
4. Insert the installing arbor through the hole in the arch of the tool.
- Press piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch.
- The pin guide will fall out of the connecting rod as the piston pin is pressed inch

NOTE: Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.

5. Install piston rings, apply engine oil around piston and piston rings.






6. Position each piston ring end gap as far apart from neighboring gaps as possible.
- Make sure that gaps are not positioned in side rail thrust and pin directions.
7. Hold piston rings firmly in a piston ring compressor as you insert them into cylinder.
8. Make sure that the front mark of piston and the front mark (identification mark) of connecting rod are directed toward front of engine.






9. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match.
10. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side.
11. Tighten the connecting rod cap nuts to 35-38 Nm (350-380 kg. cm., 25-28 ft. lbs.).






12. Check connecting rod side clearance.
Connecting rod side clearance:
Standard value: 0.10-0.25 mm (0.004-0.0098 inch).
Limit: 0.4 mm (0.0157 inch).