User Manual

Page 6-24
200 ENGINE ASSEMBLY
Installation
Refer to Figure 6-24.
1. Rotate crankshaft so that the journals for the
No. 1 and No. 6 cylinders are at bottom dead
center.
2. Place piston, marked No. 1, on a clean, flat
surface. Rest the piston and rod assembly
on the piston crown with the rod upward.
3. Apply a light coat of clean engine oil to
piston and rings.
4. Apply a light coat of clean engine oil to
inside surface of the piston ring compressor
J 23442 or PT7070-A.
5. Install ring compression tool by slipping it
over the rod and down over the piston skirt
with tapered end downward.
Figure 6-24 — Piston and Connecting Rod Installation
6. Carefully slide tool downward while guiding
rings into the ring grooves.
7. Continue sliding tool downward until it
contacts the surface on which the piston
crown is resting.
MACK E7 6-cylinder engines use a special type
of connecting rod bearing. Each bearing half has
a different thickness. The upper (rod) bearing half
is thicker than the lower (cap) half. This design
increases the load-carrying capacity of the upper
bearing and provides longer bearing life.
The hole in the upper connecting rod bearing
must be aligned with the oil passage in the
connecting rod. Otherwise, damage to the
bearing, rod and crankshaft journal will result.
8. Position an upper (rod) bearing into the
connecting rod. Align tab in the bearing with
notch in the rod. Be sure that the hole in the
bearing aligns with the oil passage in the
rod.
9. Apply a light coat of clean engine oil to
bearing surface.
10. Apply a light coat of clean engine oil to
inside surface of the No. 1 cylinder sleeve.
11. With the ring compression tool in place,
position piston and rod assembly into the
No. 1 cylinder. The arrow and word FRONT
on both the piston crown and the connecting
rod must be facing the front of the engine.
Apply downward pressure to the ring
compression tool, keeping it in contact with the
cylinder sleeve, until the top ring has passed into
the cylinder sleeve. Otherwise, damage to the
rings may result.
12. Make sure connecting rod aligns with journal
and, using a hammer handle, carefully push
piston into cylinder until piston crown is
below the surface of the sleeve.
5-101.bk Page 24 Friday, March 17, 2006 11:05 AM