a) remove pistons
1. Remove the piston rings from the piston with tool (A).
2. Remove retaining ring (4), piston pin (1) and connecting rod (2) from the piston.
3. Remove connecting rod bearings (3) from the connecting rod and the connecting rod cap.
4. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295-02 for more information about removal and installation of piston pin bearings.
5. Heat the connecting rod in an oven to a temperature of 350° to 500°F (176° to 260°C). Never use a direct flame to heat a connecting rod. Put connecting rod (6) in position on the base plate of tooling (B). Put a new bearing (5) on the adapter of tooling (B). Put the adapter in position in the connecting rod and the base plate of tooling (B).
6. Install the pusher adapter (8) and pusher (7) from tooling (B) on the adapter.
NOTE: The old bearing is pushed out by tooling (B) as the new bearing is installed.
7. Use tooling (B) to push the new bearing (5) into the connecting rod (6) until the push adapter of tooling (B) makes full contact with the connecting rod surface.
8. Remove the connecting rod and old piston pin bearing from tooling (B).
9. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension for a 5S6360 Rod is 1.5017 ± .0003 in. (38.143 ± 0.008 mm). The correct dimension for a 5S2793 Rod is 1.7012 ± .0003 in. (43.210 ± 0.008 mm). The maximum permissible clearance between the bearing and piston pin (worn) must not be more than 0.08 mm (.003 in.).
1. When old pistons are used, clean the piston grooves with an acceptable ring groove tool.
2. Install the connecting rod bearings in the crankshaft end of the connecting rod. Make sure the tab on the back of the bearings are in the grooves of the connecting rod and cap.
3. Put connecting rod (1) in position in the piston with bearing tab grooves (2) and number identification on the same siDDe as the “V” mark on the top of the piston.
4. Install piston pin (3) and retaining ring (4).
5. For correct piston and ring clearances, see PISTONS AND RINGS in SPECIFICATIONS.
6. Install the oil ring spring in the oil ring groove of the piston.
NOTE: The oil ring must be installed on the piston with the ring end gap 180° from the oil ring spring joint.
7. Install the oil ring on the piston with tool (A).
8. Install the intermediate piston ring with the side that has the mark “UP-2” toward the top of the piston with tool (A).
9. Install the top piston ring with the side that has the mark “UP-1” toward the top of the piston. Make sure piston ring end gaps are 90° apart before the pistons are installed.
a) install pistons