Install the upper bearing shell in the connecting rod. If used bearing shells are to be installed, each bearing shell must be installed in its original location.

NOTE: The tang (1) of the bearing shell must be in the slot (2) of the rod.

Use clean Lubriplate® 105, or equivalent, to lubricate the bearing shell.

Apply a heavy film of clean 15W-40 lubricating oil to the liner.

Lubricate the piston and the ring assembly by hand with clean 15W-40 lubricating oil. Dipping is okay, but draining is very difficult because the piston does not have drain holes. If dipping, only dip up to the pin bore, then hand lubricate it and the remaining skirt.

Install connecting rod guide pins, Part Number 3375601.

Use piston ring compressor, Part Number 3822736, to compress the piston rings.

Use the accessory drive pulley to rotate the crankshaft.

Rotate the crankshaft to position the journal for the connecting rod at bottom-dead-center.

CAUTION  To reduce the possibility or piston damage, do not use a metal object to push the piston into the liner.

The tang of the connecting rod must be toward the camshaft side of the cylinder block.

CAUTION  Do not use a hammer or its equivalent to install the piston into the cylinder liner. The piston rings can be damaged.

Install the connecting rod into the cylinder liner and push the piston down. If the piston does not move freely, remove the piston.

Inspect for broken or damaged rings.

When installing the connecting rod, pay close attention to make sure the rod is aligned with the crankshaft rod journal. If the rod is misaligned, it can bind or scrape the crankshaft connecting rod journal side walls.

Use the guide pins to pull the connecting rod against the crankshaft.

Remove the guide pins.

Install the bearing in the connecting rod cap.

The tang (2) of the bearing must be in the slot (1) of the connecting rod cap.

Lubricate the bearing shell with Lubriplate® 105, or equivalent. Lubricate the connecting rod capscrew threads and the washer face with 15W-40 lubricating oil.

CAUTION  The connecting rod cap alpha characters must match the alpha characters on the connecting rod and must be installed with the characters aligned to prevent damage to the connecting rods and crankshaft. The locking tang of the connecting rod cap must be toward the camshaft side of the cylinder block.

Install the connecting rod caps and capscrews.

The connecting rod has changed on the 1994 Certification Level engine to accommodate the increased loading of the articulated pistons. The torquing procedure for the connecting rod capscrews has also changed. The new torque specification is 129 N•m [95 ft-lb] plus 60 degrees ± 5 degrees.

To facilitate this new torquing procedure, the torque angle socket gauge, Part Number 3824520, was developed.

The torque angle socket is marked with a zero (start) point, a specification window, and an Out-of-Limits (OOL) line.

The tightening procedure is to pre-tighten both of the capscrews to 129 N•m [95 ft-lb].

With the socket on the capscrew, draw a line from the zero (start) point across the capscrew head to a point on the rod cap.

This line is the gauge line for the angle portion of the specification (60 degrees ± 5 degrees).

With the “0” line on the socket gauge aligned with the line on the connecting rod cap, tighten the capscrew.

With the socket gauge in position, check to see if the fixed line (on the connecting rod cap) is within the window on the gauge.

If the fixed line is between the “0” line and the “Out-of-Limits (OOL)” line, tighten or loosen the capscrew until the line is within the window.

If the fixed line is past the “OOL” line, replace the capscrew and repeat the tightening sequence.

Measure the connecting rod side clearance.

Connecting Rod Side Clearance

NOTE: If the side clearance does not meet these specifications, do the following.

Remove the rod caps. Inspect the rod caps for dirt, damage, and correct bearings.

Install the connecting rod caps and tighten the connecting rod capscrews.

Measure the side clearance again.

NOTE: If the side clearance does not meet the specifications, the connecting rod must be replaced.