SERVICE MANUAL
CONNECTING RODS, PISTONS, RINGS & SLEEVES
Section 5
NOTE: If bolts will not screw in by hand, re-clean the
rod threads and try a new bolt. If a new bolt does
not screw in freely, the rod must be discarded.
Whenever new bolts are used in a rod, they must be
torqued to 175 N•m (130 lb-ft), loosened, and
retorqued three times.
Figure 33. - Connecting Rod and Piston Marking in
Relation to the Camshaft
1.
Numbers face away from camshaft.
2.
Markings on top of piston face toward
camshaft.
8.
Install the remaining rods and pistons in the
same manner.
NOTE: The connecting rod bearings must be fitted.
Bearing clearance checked and connecting rod end
play checked, as outlined previously in this section,
prior to continuing with engine assembly.
9.
Install cylinder head & valves as described in
Section 3.
NOTE: Whenever the cylinder head is removed valve
lash must be adjusted as described in Section 3.
10.
Install
Manifolds
and
Turbocharger
(if
equipped) as described in Sections 2 and 1
respectively.
11.
Install the oil pan with a new gasket.
12.
After installation of new pistons and/or new
piston rings, the engine must be “RUN-IN”
as follows:
NOTE: Do not run the engine at low or high-idle
speeds for ‘long periods after installing new rings or
sleeves, as rings will not seat during idle operation.
a.
Install the necessary diagnostic instruments
similar to procedures outlined in diagnostic
manual
ISS-1526-3
for
construction
equipment, CGES-240 for OEM and On
Highway Truck, GSS-1460 and GSS-1482
for Agricultural Equipment. Fill engine
crank-case with lubricating oil as specified in
specific operation and maintenance manual.
b.
Perform
a
60
minute
(minimum)
DYNAMOMETER or IN-VEHICLE Run-In
Procedure as follows:
-ENGINE RUN-IN SCHEDULE-
1.
Motor engine (w/dynamometer) or idle Engine
(In-vehicle) at “No Load” @ 550-600 RPMI and
check for leaks in water, lube oil, fuel and air-
induction systems. Time required: 5 minutes.
2.
Operate engine at 3/4 rated speed (RPM) and
1/2 rated load for that speed. Time required: 5
minutes.
3.
Operate engine at ¾ rated load and rated speed
(RPM). Time required: 5 minutes.
CGES-185-3
PRINTED IN UNITED STATES OF AMERICA
Page 29
