5-101.bk Page 25 Friday, March 17, 2006 11:05 AM
200 ENGINE ASSEMBLY CHECKING RUNNING CLEARANCE Do not force the piston. This indicates an incorrectly aligned ring. Remove piston, correct the problem, and reinstall. Before pushing piston all the way down in the sleeve, check to see if piston cooling nozzle is aligned with the nozzle clearance notch provided in the lower end of the piston skirt. If it is not aligned, damage to piston or spray nozzle may result. 13. Align rod with the journal and continue pushing piston into sleeve while guiding rod end (to clear piston cooling nozzle), until rod is in position on the crankshaft journal. 14. Ensure that the correct mate to the upper rod bearing and alignment sleeves, if applicable, are positioned in the rod cap. Perform a running clearance check at this connecting rod journal before installing the next piston in Step 15.
Perform running clearance check after installing each piston. Damage to engine may result if clearance is not within specification. 15. After performing running clearance check, repeat above installation procedures to install the No. 6 piston.
1. Place a section of Plastigage on the cap bearing and assemble cap to rod. 2. Apply a light coat of oil on threads of the rod cap capscrews and secure cap. 3. Torque capscrews to 150 lb-ft (203 N폷m) using torque wrench J 24407 or equivalent. 4. Remove capscrews and cap, and check the bearing running clearance. 5. Using a Plastigage width chart, measure width of the Plastigage and remove it from bearing. 6. If clearance is not within specification, correct as required. Make sure to use the correct size bearing. 7. If clearance is less than specified, also check behind bearing for dirt, chips or burrs which would prevent the bearing from seating properly. 8. Reposition cap on journal. Lubricate new capscrews with clean engine oil, install the capscrews and torque to 150 lb-ft (203 N폷m) using torque wrench J 24407 or equivalent.
If cap and rod are not properly aligned, bearing and rod damage may result.
16. Rotate crankshaft so that the journals for the No. 2 and No. 5 cylinders are at bottom dead center. Follow above installation procedures to install the No. 2 and No. 5 pistons. Repeat procedures to install the No. 3 and No. 4 pistons.
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