Page 296
REPAIR INSTRUCTIONS, PART 1
Do not force the piston. This indicates an
incorrectly aligned ring. Remove the piston
assembly, correct the problem, and then reinstall
it. Make sure the compressor tool remains in
contact with the cylinder sleeve until the piston
clears the tool. If contact is not maintained,
damage to the rings may result.
Before pushing the piston all the way down in the
sleeve, check to see that the piston cooling
nozzle is aligned with the nozzle clearance notch
provided in the lower end of the piston skirt as
shown in Figure 332. Damage to piston or spray
nozzle may result if it is not aligned.
332
Figure 332 — Piston Skirt/Cooling Nozzle Alignment
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 333)
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 the engine may
result if clearance is not within specification.
333
Figure 333 — 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 place the cap and bearing in
position on the rod.
2. Apply a light coat of oil on the threads of the
rod cap capscrews and install the screws.
3. Angle torque the capscrews to 30 lb-ft
(41 N
폷
m) plus 90 degrees using torque angle
gauge set BT 91104, or equivalent.
1. Cooling Nozzle
2. Clearance Notch
3. Connecting Rod
1. Connecting Rod
2. Bearing Cap
5-111.bk Page 296 Monday, July 10, 2006 2:26 PM
Summary of Contents for ASET AC
Page 6: ...TABLE OF CONTENTS Page iii TABLE OF CONTENTS 5 111 bk Page iii Monday July 10 2006 2 26 PM...
Page 14: ...INTRODUCTION Page 1 INTRODUCTION 5 111 bk Page 1 Monday July 10 2006 2 26 PM...
Page 23: ...Page 10 NOTES 5 111 bk Page 10 Monday July 10 2006 2 26 PM...
Page 96: ...COMPONENT LOCATOR Page 83 COMPONENT LOCATOR 5 111 bk Page 83 Monday July 10 2006 2 26 PM...
Page 99: ...Page 86 NOTES 5 111 bk Page 86 Monday July 10 2006 2 26 PM...
Page 100: ...TROUBLESHOOTING Page 87 TROUBLESHOOTING 5 111 bk Page 87 Monday July 10 2006 2 26 PM...
Page 140: ...MAINTENANCE Page 127 MAINTENANCE 5 111 bk Page 127 Monday July 10 2006 2 26 PM...
Page 153: ...Page 140 NOTES 5 111 bk Page 140 Monday July 10 2006 2 26 PM...
Page 383: ...Page 370 NOTES 5 111 bk Page 370 Monday July 10 2006 2 26 PM...
Page 479: ...Page 466 NOTES 5 111 bk Page 466 Monday July 10 2006 2 26 PM...
Page 480: ...SPECIFICATIONS Page 467 SPECIFICATIONS 5 111 bk Page 467 Monday July 10 2006 2 26 PM...
Page 505: ...Page 492 NOTES 5 111 bk Page 492 Monday July 10 2006 2 26 PM...
Page 513: ...Page 500 NOTES 5 111 bk Page 500 Monday July 10 2006 2 26 PM...
Page 519: ...Page 506 NOTES 5 111 bk Page 506 Monday July 10 2006 2 26 PM...
Page 520: ...APPENDIX Page 507 APPENDIX 5 111 bk Page 507 Monday July 10 2006 2 26 PM...
Page 528: ...INDEX Page 515 INDEX Index fm Page 515 Monday July 10 2006 2 48 PM...
Page 535: ...Page 522 NOTES Index fm Page 522 Monday July 10 2006 2 48 PM...