INSTALL PISTON ASSEMBLY AND CYLINDER (Refer to Figure 7.)
This procedure applies to either piston assembly and cylinder.
Snap Ring Pliers (or Needle Nose)
Socket, Socket Wrench, 14 mm
Torque Wrench, 50 ft. lb. capacity
Piston rings installed
If removed during engine disassembly, install and tighten securely eight cylinder studs (1).
The cylinder is off-set. Ensure cylinder is correctly positioned inside cylinder studs.
Position cylinder (2) inside cylinder studs (1).
Turn flywheel so that crankshaft journal (3) for cylinder being installed is at TDC.
Insert connecting rod (4) in piston (5). Install piston pin (6) through piston (5) and connecting rod (4). Install the two
snap rings (7) to hold piston pin (6) in place.
When installing piston, combustion chamber recess must be positioned toward injector
side of engine. Bottom end of cylinders are chamfered for easier piston ring installation.
Insert piston assembly (4 thru 7) up into bottom end of cylinder (2) until piston rings have passed into cylinder.
Quantity of cylinder gaskets may vary. Ensure that the same number of gaskets that were
removed are replaced.
Install cylinder gasket (8). Set cylinder (2) in crankcase (9). Press cylinder (2) into crankcase (9).
Bearing halves are keyed together one way. Connecting rod and rod cap are also keyed
together one way.
Align and install new bearing half (10) on rod cap (11).
Position rod cap (11) on underside of crankshaft journal (3).
Align and install new bearing half (10) on the topside of crankshaft journal (3).
10. Position connecting rod (4) around crankshaft journal (3). Insert and start cap screws (12) in rod cap (11).
11. Install and torque cap screws (12) to 26 to 30 ft. lbs. (35-41 Nm).