SERVICE MANUAL CONNECTING RODS, PISTONS, RINGS & SLEEVES Section 5 f. Take    readings    at    three    or    four    points around   the   sleeve   and   use   the   average reading  to  determine  which  shim,  if  any,  is needed to bring the protrusion within the 0.05 mm (0.002 in.) 0.13 mm (0.005 in.) specification. NOTE:    Shims  are  available  in  0.005  mm  (0.002  in.), 0.10  mm  (0.004  in.),  0.25  mm   (0.010   in.),   0.51   mm (0.020  in.)  and  0.81  mm  (0.032  in.)  thicknesses  In  a package. 3. Install  the  necessary  Shims  and  “O”  Rings as follows: a. Remove  the  clamping  bolts  and  washers. Clean the TOP  deck  of  the  crankcase  and the cylinder sleeve counterbore.  Clean the sleeve. b. Install    the    shim    (if    necessary)    in    the counterbore as shown in Fig.  32. Figure 32.  - Shim Placement c. Coat the sealing “O” Rings with clean engine oil  and  install  them  into  the  grooves  in  the sleeves (without twist).  The .rings MUST be installed  in  the  following  order:  BOTTOM, CENTER and TOP. NOTE:    Be sure the “O” Ring is properly aligned in the groove. d. Brush  the  sealing  ring  contacting  surface  in the crankcase with clean engine oil. e. Install   the   sleeve   carefully   into   the   same bore it was removed from.  Press into place by hand. f. Check sleeve protrusion as previously described in (2a-f) In this section. Install Pistons and Connecting Rods as follows: 4. Coat the piston and piston ring compressor (PLT-500-2,  04-464-2  or  SE-1680)  for  400 series with clean lubricating oil. 5. Install the piston end rod assembly into the piston ring compressor. NOTE:      The   piston   and   rod   assemblies   can   be installed by turning the crankshaft only three times. Position  the  No.    I  and  6  crankpins  at  TDC.    Install the  No.    1  and  6  piston  assemblies.    Repeat  this procedure  for  the  Nos.    2  and  5  and  Nos.    3  and  4 piston and rod assemblies. 6. Coat   the   cylinder   sleeve   generously   with   clean lubricating  oil.    Install  the  compressor,  with  piston and rod, into the cylinder sleeve.  The numbers on the rod must face away from the camshaft while the markings   on   top   of   the   piston   faces   toward   the camshaft  side  of  the  engine  as  shown  in  Fig.    33. Push  down  on  the  piston  carefully  until  it  is  in  the cylinder  sleeve.    Avoid  striking  the  sleeve  with  the connecting rod. 7. Coat the connecting rod journal and connecting rod bearings with clean engine oil. a. Install  the  upper  half  of  the  bearing  in  the connecting  rod  and  pull  the  rod  down  onto the journal. b. Install  the  connecting  rod  bearing  cap  with the  numbered  side  of  the  cap  matching  the numbered side of the rod. c. Install  the  bolts  and  tighten  to  80  N•m  (60 Ibf-ft) torque, then tighten to 175 N•m (1 30 Ibf-ft) torque. CGES-185-3 PRINTED IN UNITED STATES OF AMERICA Page 28