User Manual

200 ENGINE ASSEMBLY
Page 6-25
Do not force the piston. This indicates an
incorrectly aligned ring. Remove piston, correct
the problem, and reinstall.
Before pushing piston all the way down in the
sleeve, check to see if piston cooling nozzle is
aligned with the nozzle clearance notch provided
in the lower end of the piston skirt. If it is not
aligned, damage to piston or spray nozzle may
result.
13. Align rod with the journal and continue
pushing piston into sleeve while guiding rod
end (to clear piston cooling nozzle), until rod
is in position on the crankshaft journal.
14. Ensure that the correct mate to the upper
rod bearing and alignment sleeves, if
applicable, are positioned in the rod cap.
Perform a running clearance check at this
connecting rod journal before installing the
next piston in Step 15.
Perform running clearance check after installing
each piston. Damage to engine may result if
clearance is not within specification.
15. After performing running clearance check,
repeat above installation procedures to
install the No. 6 piston.
16. Rotate crankshaft so that the journals for the
No. 2 and No. 5 cylinders are at bottom dead
center. Follow above installation procedures
to install the No. 2 and No. 5 pistons. Repeat
procedures to install the No. 3 and No. 4
pistons.
CHECKING RUNNING CLEARANCE
1. Place a section of Plastigage on the cap
bearing and assemble cap to rod.
2. Apply a light coat of oil on threads of the rod
cap capscrews and secure cap.
3. Torque capscrews to 150 lb-ft
(203 N폷m) using torque wrench J 24407 or
equivalent.
4. Remove capscrews and cap, and check the
bearing running clearance.
5. Using a Plastigage width chart, measure
width of the Plastigage and remove it from
bearing.
6. If clearance is not within specification,
correct as required. Make sure to use the
correct size bearing.
7. If clearance is less than specified, also
check behind bearing for dirt, chips or burrs
which would prevent the bearing from
seating properly.
8. Reposition cap on journal. Lubricate new
capscrews with clean engine oil, install the
capscrews and torque to 150 lb-ft
(203 N폷m) using torque wrench J 24407 or
equivalent.
If cap and rod are not properly aligned, bearing
and rod damage may result.
5-101.bk Page 25 Friday, March 17, 2006 11:05 AM