Connecting Rod: Service and Repair

Removal

Cylinder Block Assembly:

Ream Cylinder If Necessary Prior To Piston Removal:

1. If carbon has accumulated on top of the bore, ream the cylinder before removing pistons.

Check Connecting Rod Thrust Clearance:

2. Measure the connecting rod thrust clearance. If it exceeds 0.012 in. (0.3mm) then replace the connecting rod.

Place Matchmark On Cap And Connecting Rod:

3. Place matchmarks on the cap and connecting rod. Remove the nuts, connecting rod end cap and lower bearing.

Cover Rod Bolts With Short Piece Of Hose:

4. To prevent damage to the cylinder wall, cover the connecting rod bolts with a short piece of hose.
5. Slide the piston and connecting rod assembly up through the top of the cylinder block.

Installation

Cover Connecting Rod Bolts:

1. Cover the rod bolts with a small piece of hose.

Proper Position Of Ring Gap:

2. Position the ring gaps as shown in the illustration.

Push The Connecting Rod/Piston Assembly With The Marks Facing Forward:

3. Push in the piston/connecting rod assembly with the notch facing forward as shown. The mark on the connecting rod should also face towards the front.

Insert Piston Using Ring Compressor:

4. Using a ring compressor, insert the piston/connecting rod assembly into the cylinder.

Match Marks And Install Connecting Rod End Caps:

5. Align the matching rod and cap marks and install the rod cap. Torque to 31-34 ft.lbs (4.2-4.8 kgm).

Check Crankshaft For Smooth Rotation:

6. After the pistons have been installed, make sure the crankshaft rotates smoothly.

Check Connecting Rod Thrust Clearance:

7. Check connecting rod thrust clearance, if it exceeds 0.012 in. (0.3 mm) replace the connecting rod.