Page 51 - Tech handbook 2019 rev 6 whyperlinks

• The connecting rod and rod cap are a matched set. This is easily verified with a
stamped number on the rod and the cap that must match. Each rod and cap number
must be verified by both technicians and recorded on the Overhaul Data Sheet.
• Each assembly consisting of a piston, wrist pin, 2 c-clips, connecting rod and rod
bearing set should all be assembled at one time. Only new engine oil is to be used

for pre-lubrication.
• During this pre-assembly only one connecting rod and rod cap can be separated at a
time. During installation of the piston packs only one connecting rod and rod cap can
be separated at a time. This will prevent any chance of a connecting rod and cap
from getting swapped.
• As each piston pack is installed the piston ring gaps will be staggered, the bearing in
the connecting rod must be checked to make sure it’s still in the proper position
before installing the rod cap and the connecting rod bolts must be torqued before
installing the next pack.

• As each piston pack is installed and torqued each cylinder needs to be covered to
keep debris or parts from being dropped into the cylinders.
• As each set of pistons are installed and the engine is being barred over any
resistance felt must be inspected. This could be a sign of incorrect bearings,
incorrect bearing crush etc.
• Once bottom end is assembled crank end play and connecting rod gaps should be

measured against engine specific specification. These can be found in the engine
specific Overhaul data capture sheet.
• Refer to the document section for the applicable TI’s, ST’s and Maintenance Tasks.

Crankcase and Oil Pan

• Once the bottom end is back together the oil pan must be completely cleaned,
photos taken and temporarily install the side covers to keep dirt and debris out of
the crankcase.

Cylinder Heads, Valve Train and Cam Shaft

• Inspect all head studs and torque any loose ones to spec. There is no spec for the
length of the studs after being properly tightened but any stud more than a few
millimeters longer than the others should be replaced.

9 | P a ge