Pistons & Connecting Rods: Installation
NOTE:
For ease of installation of piston pin, connecting rod should be heated to 280°C (536°F). Heat upper connecting rod only. Use commercial thermocolor material to determine correct temperature. When thermocolor material changes from black to green, temperature is correct for installation.
- Align notch on piston and connecting rod so that proper sides will be facing front of engine. Install piston pin guide through piston and connecting rod. Coat piston pin with clean oil. Install piston pin into opposite side of piston. Install piston pin into piston and connecting rod assembly using piston pin service set.
- Select a set of new piston rings. Measure piston ring gap using a feeler gauge. Increase piston ring gap by carefully filing off excess material if piston ring gap is below specifications. Measure piston ring side clearance using a feeler gauge. If piston ring is too thick, try another piston ring.
- If no piston ring can be found that fits to specifications, piston ring may be ground to size with emery paper placed on a sheet of glass. Install a piston oil ring, expander, then second piston oil ring to bottom ring groove of piston. Install second compression ring to middle ring groove of piston. Install top compression ring to top ring groove of piston. See Fig 1. Use a piston ring expander to install piston rings. Do not expand piston rings beyond expansion necessary for installation.
- Stagger piston oil rings, oil ring rail gaps, second compression ring, and top compression ring in relation to notch on top of piston. See Fig 2. Lubricate cylinder wall and piston rings with clean engine oil. Install piston using universal piston ring compressor and a wood handle. Guide lower connecting rod end to prevent damaging crankshaft journal. Install connecting rod cap and bearings.
- Install connecting rod cap bearing bolts. Tighten connecting rod cap bearing bolts to 35 N.m (26 ft. lbs.). Using angular torque gauge, tighten bolts one turn of 45 degrees plus 15 degrees. Install engine block lower support bracket/splash shield bolts. Tighten engine block lower support brace/splash shield bolts to 35 N.m (26 ft. lbs.).
- Install oil pump pickup tube. Install oil pump pickup tube bolts. Tighten oil pump pickup tube bolts to 8 N.m (71 INCH Lbs.). Install oil pan. Install cylinder head with intake manifold and exhaust manifold attached.