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1-24
GROUP 1-
ENGINES AND EXHAUST SYSTEM
IMPROPER SEATING
TAPERED JOURNAL
RADIUS RIDE
fATIGUE
fAILURE
Al021-A
FIG.
54-Typical Bearing Failures
3. Remove the oil pan
and related
parts. Remove the oil pump inlet
tube and the oil pump.
4.
Turn the crankshaft until the
piston
to be removed is
at
the
bottom
of
its travel
and
place
a
cloth
on
the
piston head to
collect
the
cuttings.
Remove any ridge
and/or deposits
from the upper
end of
the
cylinder
bores.
Remove the
cylinder
ridge
with
a
ridge
cuttcr.
Follow the
in~
structions
furnished by the tool man-
ufacturer. Never cut into the ring
travel
area in excess of
"%2
inch
when
removing ridges.
S. Make sure all
the
connecting
rod
caps
are marked
so that
they
can
be installed
in
their original locations.
Remove the connecting rod
cap.
6.
Push
the
connecting rod and
piston
assembly out
the top
of
the
cylinder
with the handle
end of
a
hammer. Avoid
damage to
the
crank-
pin or the cylinder wall when
remov-
ing the piston
and
rod.
INSTALLATION
1.
Clean
the
oil pump inlet tube
screen, and
the oil
pan
and
block
gasket surfaces.
2. Oil the piston rings, pistons,
and cylinder
walls
with
light
engine
oil.
3.
Be sure
to
install
the
pistons in
the
same cylinders from which they
were
removed, or
to
which
they
were
fitted. The connecting rod and bear-
ing caps are
numbered
from 1 to 6
beginning at
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 cylin-
der
to
another, new bearings should
be
fitted
and the connecting rod
should
be
numbered to correspond
with
the new
cylinder
number.
4.
Make sure
the
ring
gaps
are
properly spaced around the circum-
ference
of
the piston
.
Install
a
piston
ring
compressor
on
the piston and
push the piston in
with a
hammer
handle until it is
slightly
below the
top
of
the
cylinder
(Fig.
55).
Be
sure
to
guide
the
connecting rods
to
avoid
damaging
the'
crankshaft
journals.
Install
the piston with
the notch in
the piston
head
toward the front
of
the
engine.
5. Check the
clearance of
each
bearing following the
procedure
under
"Connecting Rod Bearing Replace-
ment."
6. After the bearings have been
fitted, apply
a
light coat of
engine
oil
to
the journals and bearings.
7. Turn the
crankshaft
throw to
the bottom of
its
stroke, then push
the piston all the
way
down until
the
connecting
rod bearing
seats on
the
crankshaft journal. Install the con-
necting
rod
cap. Torque the nuts to
specifications.
8. After the piston and
connecting
rod
assemb lies
have been installed,
check the connecting rod
side
clear-
ance on
each crankshaft
journal (Fig.
56).
9. Install the
oil
pump
and
the oil
pump inlet tube. Install the
oil
pan
and
related parts.
FIG.
55-Piston Installation
FIG.
56-Connecting Rod Side
Clearance
10. Refer
to "Cylinder
Head
In-
stallation" and
install the cylinder
head
and
related parts.
11.
Fill and bleed the cooling sys-
tem.
F
ill
the
crankcase.
12.
Start the engine and check for
oil pressure. Operate
the
engine at
fast
idle
and
check for oil and coolant
leaks.
13.
Check and adjust
the ignition
timing.
DISASSEMBLY
1. Remove the bearing inserts
from the
connecting
rod and cap.
2. Mark the pistons and pins
to
assure
assembly with
the
same
rod
and
installatio~
in the same cylinders
from
whk;,
they
were
removed.
3.
Remove
the
piston pin from
the
piston
and
connecting rod (Fig. 57).
Remove the piston
rings.
ASSEMBLY
The piston,
connecting
rod,
and
related parts
are shown
in Fig. 58.
Check the fit of a
new piston
in
the
cylinder bore
before assembling
the
piston
and piston pin
to the
connect-
ing rod.
The piston pin bore of a connect-
ing rod
and
the diameter of the
piston pin must be within
specifica-
tions. Refer to Part 13-4.
1.
Apply a light coat of engine oil
to all parts. Assemble
the
piston
to
the
connecting
rod with the oil
squirt
hole
in
the
connecting
rod and
the
indentation in
the
piston
positioned
as
shown
in Fig. 59.
2. Start the piston pin
in
the pis-
ton and connecting rod. Draw the
piston pin through
the piston
and
connecting rod until
the end of
the
pin
seats
in Detail
2
(Fig. 60).
3.
Follow the instructions con-
tained on
the
piston ring
package
and
install
the piston rings.
4.
Check
the ring
side
clearance
of
the
compression rings with a
feeler
gauge
following step 6 under
"
Fitting Piston Rings."
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