Connecting Rod: Service and Repair

Fig. 4 Piston Installation. Piston Marked ``.9'' In Direction Of Installation:

1. Prior to removal, mark pistons and rods to match cylinder number.
2. Remove circlips from piston, press pin out by hand and separate assembly. If pin is too tight in bore, heat piston to approximately 140°F.
3. Check piston to cylinder wall clearance at right angles to piston pin, 3/8 inch from top and bottom and in center of travel.
4. Check that ring end gaps are within specifications by installing ring approximately 9/16 inch from top of cylinder and centering with an inverted piston.
5. Assemble piston and rod combinations with casting marks on rod and markings on piston crown, Fig. 4 facing timing belt. If piston pin is tight in pin bore, heat piston to approximately 140°F to aid installation. Ensure pin attaching locks are properly seated.
6. Install piston rings with TOP markings facing piston crown. Side clearance for compression rings should measure 0.002-0.004 inch on upper rings and 0.002-0.003 inch on lower rings and must not exceed 0.008 inch. Side clearance for oil rings should measure 0.001-0.002 inch and must not exceed 0.006 inch.
7. Install assemblies with piston marking facing timing belt, using a ring compressor. Ensure connecting rod side clearance is less than 0.004 inch. Ensure ``stretch'' type connecting rod bolts are used. Bolts are not reusable, and must be replaced during assembly. During installation, tighten nuts to specified value, then turn each nut an additional 1/2 turn to obtain proper stretch.