The oil pan and the cylinder head should be removed before the displacement of the piston and connecting rod assembly. Feel your finger to the upper limit of the ring travel, about 1/4-inch below the top of each cylinder; this should have no ridges as a result of carbon deposition or wear, or it will cause piston breakage; if in any case there are ridges, they must be entirely removed by a special tool as directed by the manufacturer. Once the ridges of the cylinder have been removed, position the engine such that the
Crankshaft is facing upward and take out the balance shaft assembly. Prior to removing main bearing cap assembly and connecting rods, measure the connecting rod endplay using a feeler gauge, make sure the play is not more than the stated limits, otherwise new connecting rods can be required. Mark the connecting rods and caps with paint or marker where there are none, and firmly tighten the connecting rod cap bolts until they are easy enough to loosen. Carefully remove the number one connecting rod cap and the bearing insert and then force the connecting rod/piston assembly out through the top of the engine, be sure that all the ridges are removed. It should then be repeated to the rest of the cylinders and once removed, the connecting rod caps and bearing inserts should be reassembled in their respective rods with the old inserts being left as they provide protection against damage. The connecting rods and pistons can then be inspected and overhauled. Check the end gaps of the rings, and the clearance at the piston ringside, before putting in the new rings. Prepare the assemblies of piston/connecting rod and new sets of rings to match. Install the upper ring into the first cylinder and test the end gap using feeler gauges and make sure that it fits within the values specified; in case of any alterations, the ends of the ring can be carefully filed. Do the same with each of the rings and fit them on the pistons beginning with the oil control ring, then the middle ring, and the top ring with the right orientation. Prior to installation, the walls of the cylinder should be clean, the top edge of the individual cylinder bores should be chamfered, and a crankshaft should be installed. Wipe clean the bearing surfaces of the connecting rod and cap then fit in the new upper bearing insert and then make sure that it fits in without lubrication. Install piston rings by spacing the gaps of the piston rings at intervals of 90 degrees, lubricating the piston ring, and then installing the piston ring with the help of a piston ring compressor. Install the piston/connecting rod assembly into the cylinder bore with connecting rod journal in the bottom dead center position and apply oil to the walls of the cylinder. Precisely set the assembly where it will not meet with resistance. When the installation is complete, examine the connecting rod bearing oil clearance with Plastigage so that bearing inserts are of the right size and condition. Wipe the faces of the bearings, put grease or assembly lube and screw on the rod cap using new bolts and tighten them to the required torque. Do the same with the rest of the assemblies, making sure that they are clean, and are facing the right way. Once all assemblies have been installed, rotate the crankshaft to test bindings and also confirm the endplay of the connecting rod, and make corrections where needed in case new parts have been fitted.