[1] – Inspect all parts for wear or damage. Replace as necessary.
[2] – Measure crankshaft connecting rod journal diameter.
[3] – Install connecting rod cap and bearing inserts on connecting rod. Install old connecting rod cap screws and tighten to 22.6—27.5 N·m (200—243 lb.-in.).
[4] – Measure connecting rod bearing diameter.
– If bearing diameter exceeds wear limit, replace bearing inserts.
– If bearing clearance (bearing ID minus crankshaft journal OD) exceeds specification, grind crankshaft connecting rod journals and install undersized bearing inserts, or replace bearing inserts and crankshaft.
[5] – With rings installed on piston, measure piston ring groove clearance. Measure several places around each piston.
If clearance exceeds maximum limit, replace rings or piston.
[6] – Measure piston ring end gap (A). Push ring into cylinder bore, using a piston, until ring is approximately 30 mm (1.2 in.) from bottom of cylinder bore (B).
[7] – Measure piston pin diameter. Measure diameter at six places.
If pin diameter is less than wear limit, replace pin.
[8] – Measure piston pin bore diameter in piston.
– If piston pin bore exceeds wear limit, replace piston.
– If bore clearance (bore ID minus pin OD) exceeds specification, replace piston, piston pin or both.
[9] – Measure piston pin bushing diameter in connecting rod.
– If bushing diameter exceeds wear limit, replace bushing.
– If bushing clearance (bushing ID minus pin OD) exceeds specification, replace bushing, piston pin or both.
Piston pin bushing is press fit. Replace bushing using a driver set. When installing
bushing, make sure to align oil hole in bushing with hole in connecting rod.
[10] –
→NOTE:
If engine has had a previous major overhaul, oversize pistons and rings may have been installed. Oversize pistons are available in 0.25 mm (0.010 in.).
Measure piston diameter perpendicular to piston pin bore at distance (A).
[11] – Measure cylinder bore diameter. (See Inspect Cylinder Bore in this Group.)
