REPAIR INSTRUCTIONS
Page 233
12. Align the rod with the crankshaft journal and
continue pushing the piston into the sleeve
while guiding the rod end to clear the piston
cooling nozzle and seat properly on the
crankshaft journal.
13. Ensure that the correct rod bearing lower
insert (matched to upper insert) and the
alignment sleeves are positioned in the
bearing cap.
14. Begin by installing the bearing cap at the
No. 1 connecting rod journal (Figure 244)
and check Running Clearance following the
procedure later in this section. Repeat the
running clearance check following the
installation of each of the remaining five
pistons.
Running clearance must be checked after
installing each piston. Damage to engine may
result if clearance is not within specification.
244
Figure 244 — Connecting Rod Cap Installation
15. Repeat the above steps to install the No. 6
piston.
16. Rotate the crankshaft so that the journals for
the No. 2 and No. 5 cylinders are at bottom
dead center and install the No. 2 and No. 5
pistons following the above steps.
17. Rotate the crankshaft so that the journals for
the No. 3 and No. 4 cylinders are at bottom
dead center and install the No. 3 and No. 4
pistons, again following the above steps.
RUNNING CLEARANCE CHECK
1. Place a section of Plastigage on the rod cap
bearing and assemble cap to the rod.
2. Apply a light coat of oil on the threads of the
rod cap capscrews and secure the cap.
3. Angle torque the capscrews to 30 lb-ft
(41 N•m) plus 90 degrees using torque
angle gauge set BT 91104, or equivalent.
The angle-torque method applies for 14-mm
capscrew part Nos. 396GC211M and
396GC212M with partial and full threaded
shanks, respectively. Intermixing the partial and
full threaded 14-mm capscrews on the same
connecting rod is permissible.
4. Remove the capscrews and cap.
5. Check the width of the Plastigage on the
removed cap using a Plastigage width chart.
After measuring width, remove the
Plastigage from the bearing.
6. If the clearance is not within specification,
correct the clearance as required:
r
If the clearance is less than specified,
check behind the bearing for dirt, chips
or burrs which would prevent the
bearing from seating properly.
r
If the bearing bores and inserts are
clean and undamaged, replace the
inserts with inserts sized to provide the
specified clearance.
7. Reposition the cap on the journal. Lubricate
capscrews with clean engine oil, install the
capscrews and tighten to the specified
torque, 30 lb-ft (41 N•m) plus 90 degrees
using torque angle gauge set BT 91104, or
equivalent.
If the cap and rod are not properly aligned,
bearing and rod damage may result.
8. Check the rod side clearance (Figure 245)
by installing a thickness gauge between the
rod and the side of the journal. Check along
the entire parting line area.
1. Connecting Rod
2. Bearing Cap
5_106_00.bk Page 233 Friday, August 4, 2000 11:17 AM
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