Remove cap from connecting rod #1 (they must be marked when removed). Wipe the old bearing shells in the connecting rod and connecting rod cap with a clean, lint-free cloth.
Connecting rod elements
1 - connecting rod cover;
2 - liners;
3 - connecting rod.
Checking the oil clearance of the connecting rod bearing
Clean the backside of the new upper bearing shell, then put it back into place on the connecting rod. Make sure the key on the bushing fits into the groove on the connecting rod. Do not hammer the bushing or scratch the bearing surface. Do not lubricate the bearing yet. Clean the back side of the second bearing and install it in the connecting rod cap. Make sure the liner key is seated in the notch in the cover and do not apply any lubricant yet.
Position the ring gaps around the piston circumference at an angle of 120°. The position of the gaps of the rings may differ from the required one by no more than 20°.
Pull pieces of plastic or rubber tubing over each connecting rod cap bolt.
Lubricate the piston and rings with clean engine oil and attach a ring compressor to the piston. The skirt should protrude about 6mm to guide the piston into the cylinder. The rings must be compressed so that they are flush with the piston.
Rotate the crankshaft until #1 crankpin is at bottom dead center. Apply a coat of engine oil to the cylinder walls.
With the piston so that the arrow or notch on the top of the piston is facing forward, carefully insert the piston into cylinder #1. The lower part of the ring press must rest on the cylinder block.
Make sure that the ring pressers are in full circumference contact with the cylinder block.
Gently press down on the top of the piston with the end of the wooden handle of the hammer while guiding the end of the connecting rod into its place on the crankshaft journal. Piston rings can pop out of the compression tool just before entering the cylinder, so pressure must be applied from above on the tool. Work slowly and if you feel resistance as the piston enters the cylinder, stop immediately. Find out the cause and eliminate it. In no case do not press hard on the piston - you can damage the rings and the piston itself.
After the piston and connecting rod are installed, the connecting rod bearing oil clearance must be checked before the connecting rod is finally screwed into place.
Cut off a piece of the correct size plastic to eliminate the gaps, slightly shorter than the width of the connecting rod bearing, and place it on the #1 crankpin, parallel to its axis.
Clean the surface of the connecting rod bearing cap, remove the protective tubes from the connecting rod bolts, and install the connecting rod cap.
Install the nuts and tighten them to the required torque in three steps. Do not rotate the crankshaft while doing this.
Unscrew the nuts and remove the connecting rod cap, being careful not to damage the plastic.
Compare the width of the squashed gap plastic to the scale on its bag to determine the gap. Compare the obtained value with the technical data.
If the clearance is not correct, the bearing shells may be the wrong size. But before you decide to replace the liners, check for dirt or oil between the liners and the connecting rod or cover. Also, check the diameter of the shaft journal. If the width of the plastic to measure the gaps is different at different ends of the strip, the shaft journal may be tapered and must be reground.
Final installation of the connecting rod
Carefully scrape all traces of plastic for measuring clearance from the surface of the shaft journal and bearing, being careful not to scratch the bearing.
Make sure the bearing surfaces are perfectly clean and apply an even coat of lubricant to both bearings. You will have to push the piston into the cylinder to get access to the connecting rod bearing - remember to put the protective tubes on the connecting rod bolts first.
Slide the connecting rod onto the shaft journal, remove the protective tubes from the connecting rod cap bolts, install the cap and tighten the nuts in three stages to the required torque.
Repeat the above procedure for the remaining pistons and connecting rods.
Check the piston group assembly.
After all pistons and connecting rods are installed, turn the crankshaft several times by hand and check if it is seizing.
Check the play of the connecting rod.
Compare the measured backlash with the technical data. If the backlash was correct before disassembly and the old connecting rods and crankshaft were used, then it should remain within the normal range. If new connecting rods or a new crankshaft were installed, the play may not be correct. In this case, it is necessary to remove the connecting rods and give it to the workshop for machining.