Location of piston ring locks on the piston
1. Clean the back of the bearing and its installation place in the connecting rod and the connecting rod cap. The lubrication holes in the connecting rod and bearing should be aligned.
2. Install the piston ring locks on the pistons as shown in the figure Location of piston ring locks on the piston.
3. Remove the rubber hose sections from the connecting rod lower head mounting studs.
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4. Lubricate the pistons and piston rings with clean engine oil.
5. Compress the piston rings onto the piston using a special piston ring compressor.
6. Turn the crankshaft to the top dead center position of the first cylinder and apply a thin layer of oil to the cylinder walls.
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7. Insert the piston with the ring compressing device into the top of the first cylinder, with the notch on the piston facing the toothed belt.
8. Using a wooden block or the handle of a hammer, push the piston into the cylinder.
9. Check the alignment of the connecting rod lower head with the crankshaft journal. If necessary, tighten the piston with the connecting rod and install the connecting rod lower head with the liner on the crankshaft journal.
10. Check the connecting rod bearing clearance.
11. Clean the back of the bearing and its installation area in the connecting rod and the connecting rod cap.
12. To check the operating clearance of the connecting rod lower end bearing, use the Plastigage method. In this case, a round plastic rod is used, which is compressed between the bearing shell and the crankshaft journal. After removing the connecting rod bearing cap, the deformed plastic rod is measured with a special template, which is included with the Plastigage. The procedure for using Plastigage is as follows. Install the connecting rods on the crankshaft without lubrication. The crankshaft journals and bearings must be completely clean and dry. Cut several pieces of plastic rod and install them on each crankshaft journal. Install the caps with the lower bearing shells and tighten the mounting bolts to the specified torque.
13. When measuring the clearance using the Plastigage method, do not rotate the engine crankshaft. Unscrew the lower connecting rod cap, remove it and apply the scale ruler printed on the package to the deformed plastic rod. By comparing the width of the deformed plastic rod with the reference width on the scale ruler, determine the clearance value. Finally, carefully clean off any traces of Plastigage material from the bearings and crankshaft.
14. Apply a thin layer of engine oil to the working surfaces of the connecting rod bearings and install the connecting rod on the crankshaft journal. Install the lower connecting rod cap and tighten the mounting nuts to the required torque.
15. Install the remaining pistons and connecting rods in the same manner.