CRANKCASE COMPONENT OVERHAUL

Table 3.05-9. Piston Pin Specifications

A

MEASUREMENT

(A) Piston pin diameter 8-1/2 in. bore

Piston pin diameter 9-3/8 in. bore

Piston pin length L5774, L5794
L7044
Piston pin fit 8-1/2 in. bore
Piston pin fit 9-3/8 in. bore

PISTON PIN CLEANING AND INSPECTION

NOTE: Always replace the pin when a new piston is

installed.

Always use approved cleaning solvents in a well

ventilated area. Contact with skin could result in
severe personal injury or death.
1. Wash piston pins in a non-volatile cleaning solution
or solvent.

INCHES (in.)

2.9987 2.9992
2.9989 2.9994
7-11/32
8-11/32
0.0012 0.0022
0.001 0.002

METRIC (mm)

76.1670 76.1797
76.1720 76.1847
186
212
0.0305 0.0559
0.0254 0.0508

5. Polish piston pins with fine grit crocus cloth to remove

minor scuff marks and scratches. Rotate each pin in a
lathe to avoid an out-of-round condition.
6. Replace pins that do not conform to specifications.
Cover piston pins with a clean plastic sheet to protect
them from dust and dirt.

CONNECTING ROD

CONNECTING ROD DISASSEMBLY

1. Remove and discard connecting rod bearings (see
Figure 3.05-22 and Figure 3.05-23).

Compressed air can pierce the skin and cause

severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
2. Thoroughly dry pins with moisture free compressed
air.
3. Visually inspect pin for etching, scoring, damage or
excessive wear. Any surface wear or defect that may be
felt is cause for replacement.
4. Measure outside diameter of piston pin in all wear
areas. Wear is usually concentrated on those surfaces
that run in pin bosses and rod bushings. Measure pin
diameter 90 degrees to wear area. Refer to Table 3.05-9
for new part tolerances of piston pin. Discard pin if
measurement is not within allowable limits.
3.05 - 24

BEARING

Figure 3.05-22. Connecting Rod

FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

SPLIT LINE OF BUSHING
(NEAR SIDE)

BEARING

CONNECTING
ROD CAP

45

Figure 3.05-23. Bearing Cap

Adequately support the

upper end of the connecting rod to avoid unnecessary stress when
pressing out old piston pin bushings.
2. Refer to Table 3.05-10 and measure piston pin
bushings for wear. If piston pin bushings are to be
replaced, press old piston pin bushings from upper
connecting rod bore and discard (see Figure 3.05-24).

PIPE PLUG

SPLIT LINE OF BUSHING

(FAR SIDE)

Figure 3.05-24. Align Rod Pin Bushing Split Line

3. Remove allen head pipe plug (1/8 in.) above pin bore
(see Figure 3.05-25).
CAPSCREW

CONNECTING
ROD

PISTON PIN
BUSHING

LUBE OIL
PASSAGEWAYS

ROD
BEARING

ROLL PIN

Figure 3.05-25. Clean Connecting Rod Oil Passageways

FORM 6296 First Edition

3.05 - 25

CRANKCASE COMPONENT OVERHAUL

Table 3.05-10. Series P/N 205507 Connecting Rod, Bushing And Bearing Specifications
A

C
B

MEASUREMENT

Rod material: Heat treated steel forging

Permissible connecting rod weight variation in an engine, within weight class A, B, or C
Connecting rod weight, Class A
Connecting rod weight, Class B
Connecting rod weight, Class C
(A) Connecting rod length, center to center
(B) Bore diameter for piston pin bushing
(C) Bushing bore diameter (diamond bored)
(Assemble 2 bushings with open ends of grooves toward inside)
Bushing press fit into connecting rod
Piston pin clearance in bushing
8.500 bore engines
9.375 bore engines
(D) Bore for crankpin bearing
Crankpin bearing diametral clearance (calculated bearing inside diameter minus
connecting rod journal diameter)
Width of connecting rod on bearing cap end
Connecting rod side clearance
Parallelism and twist limit between piston pin bushing bore and crankpin bore
NOTE: Connecting rod weight class (A, B or C) is stamped on the rod cap.

INCHES (in.)

METRIC (mm)

60.0 0.12 lb.

62.0 0.12 lb.
64.0 0.12 lb.
18.001 - 18.002
3.250 - 3.251

27.21 0.054 kg
28.12 0.054 kg
29.03 0.054 kg
457.225 - 457.251
82.550 - 82.575

3.0015 - 3.0020

76.238 - 76.508

0.0035 - 0.0065

0.0889 - 0.1651

0.0023 - 0.0033
0.0021 - 0.0031
6.625 - 6.626

0.0584 - 0.0838
0.0533 - 0.0787
168.275 - 168.300

0.0042 - 0.0081

0.1067 - 0.2057

2.905 - 2.908
0.029 - 0.041
0.001

73.787 - 73.863
0.736 - 1.041
0.0254

CONNECTING ROD CLEANING AND INSPECTION

Connecting Rod Cleaning

2. Flush out rifle drilled oil passageways with cleaning

solution (see Figure 3.05-25). Run a stiff bristle brush
through the passageways to ensure their cleanliness.

Use of caustic solutions should be restricted to a

well ventilated area. Contact with skin, clothing and
eyes could result in severe personal injury or death.

Compressed air can pierce the skin and cause

severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.

1. Submerse connecting rods in caustic hot tank (or

flush with a non-volatile cleaning solution and steam
clean) to remove all dirt, grease, oil, carbon and varnish
deposits.
3.05 - 26

FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

3. Thoroughly rinse rods and dry with moisture free
compressed air.

Always use approved cleaning solvents in a well

ventilated area. Contact with skin could result in
severe personal injury or death.
4. Clean connecting rod capscrews in solvent. Inspect
capscrews for nicks, cracks, galled or stretched threads
and other obvious damage. Replace as necessary.

Any nick, dent or ding in

the side of the rod shank
is a potential problem. Stress focused at these
points may result in metal fatigue and eventual
failure. Disregarding this information could result in
product damage and/or personal injury.
Connecting Rod - Magnaflux Application
Always carefully read the manufacturers instructions to avoid severe personal injury or death.
Using Magnaflux Dye Penetrant Test Kit (Tool
P/N 494283), inspect connecting rods for surface
cracks and defects. Look around high stress areas, such
as the pin bushing and rod bearing bores. Proceed as
follows:
1. Remove rod caps from blades.
2. To remove oily residues, apply Magnaflux Spotcheck Cleaner/Remover (SKC-S) directly to test area.
Thoroughly wipe area with a clean cloth. Repeat
procedure as necessary. Final wiping should result in a
clean cloth. Allow test area to dry.

NOTE: Wear rubber gloves to avoid hard-to-remove

stains on hands.
3. Spray test area with Magnaflux Spotcheck Penetrant (SKL-SP). Wait 1 to 30 minutes.
4. Spray Magnaflux Spotcheck Cleaner/Remover
(SKC-S) on a clean cloth (not on test area). Wiping in
one direction, remove all surface penetrant. Repeat as
necessary.
5. Spray test area with Magnaflux Spotcheck Developer (SKD-S2). Apply a thin even film. Allow film to dry
completely. Proper application dries to an even white
layer.

FORM 6296 First Edition

6. Carefully inspect test area for cracks. A bright

colored solid or dotted line marks a crack. Fine cracks
may take up to 15 minutes to appear. Large cracks can
be seen almost immediately. If crack is wide and deep,
indication will grow and spread.
7. Wipe test area clean if cracks are not found.
Thoroughly wash the rod to remove any traces of dye
penetrant.

Connecting Rod Inspection

1. Perform a careful visual inspection of connecting
rods. Verify rod shank is free of sharp nicks, dents and
gouges.

NOTE: All grinding to remove defects must be longitudinal and blend in smoothly with the surrounding areas.
Do not transverse grind.

Do not try to straighten

bent or twisted rods. A
straightened rod will revert to its bent condition after
several hours of engine operation. Disregarding this
information could result in product damage.
2. Position rod in a fixture suitable for measuring
parallelism and length.
A. Connecting rods are twisted when sides of
bearing bore (large) and pin bushing bore (small)
are not parallel (see Figure 3.05-26). Connecting
rod bores must be parallel (see Table 3.05-10)
within 0.001 in. (0.0254 mm) per inch of bushing
diameter. Discard any connecting rods that are
bent or twisted.
FEELER GAUGE

INDICATOR

Figure 3.05-26. Connecting Rod Twist Gap

B. Measure from center of bearing bore to center of

pin bushing bore (see Table 3.05-10). Distance
should be 18.001 -- 18.002 in. (457.225 -457.251 mm). Discard rod if it does not meet this
specification.
3.05 - 27

CRANKCASE COMPONENT OVERHAUL

3. Difference between left bearing bore diameter and
right is called bore taper. Discard connecting rod if taper
exceeds 0.0003 in. (0.00762 mm) (see Table 3.05-10).

age to the rod shanks.

Install brass jaw inserts

in the vise to avoid dam-

4. Place rod blade in vise with serrated split facing

upward.
5. Use Permatex Prussian Blue to check mating
surfaces of rod cap and blade for proper contact.
Proceed as follows:
!

A. Apply dye sparingly to rod blade serrations.

B. Install rod cap and tighten each capscrew equally
to 45 ft-lb (61 N m).
C. Remove connecting rod capscrews and carefully
pull cap straight back off rod blade. Inspect cap
serrations for Prussian Blue transfer. Blue dye
transfers from blade to cap wherever good
contact exists. Flanks of cap serrations must
show at least 50% surface contact. Non-contact
areas must be discontinuous with no more than
10% of void concentrated in any area.
6. If transfer of Prussian Blue does not meet above
specification, proceed as follows:
A. Using a needle nose pliers, remove 1/8 in. x 1/2 in.
hollow roll pin from rod cap (see Figure 3.05-27).

B. Slide cap back and forth on blade. If cap sticks,

use a fine triangular pattern file between serrations to lightly dress down any burrs and high
spots or to straighten any teeth that may be bent
slightly.
C. Slide cap back and forth on blade. If cap sticks
again, repeat procedure until cap slides smoothly
without sticking.
D. Use Prussian Blue to recheck mating surfaces for
proper contact. Discard rod if transfer is still
unacceptable. If transfer is within specification,
install roll pin with longitudinal groove facing cap
and end of pin flush with finished surface.
7. Check rod bearing bore for out-of-round and taper.

age to the rod shanks.

Install brass jaw inserts

in the vise to avoid dam-

8. Place rod blade in a vise with serrated split facing

upward.
9. Tighten connecting rod cap to blade, as follows:
A. Lubricate threads and under heads of four
ferryhead connecting rod capscrews with
SAE 30 engine oil.
B. Locate number 1 stamped in connecting rod
cap. Hand tighten a capscrew in this hole first.
Hand tighten remaining capscrews in positions 2
through 4 (see Figure 3.05-28).
STAMP

A
4

Figure 3.05-27. Rod Cap Roll Pin

3.05 - 28

Figure 3.05-28. Connecting Rod Cap Capscrew

FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

C. Following same numerical sequence, tighten
capscrews to 50% of final value.
D. Repeat tightening sequence, tighten capscrews
to 185 ft-lb (251 N m).
10. Inspect connecting rod bore to verify that it is clean
and smooth.

CONNECTING ROD ASSEMBLY

Replace connecting rods as necessary. The letters A,

B or C that are stamped on the cap of P/N A205507A
and P/N A205507C series connecting rods, identify the
weight classification (see Figure 3.05-30). Never use
different rod weights in the same engine (see
Table 3.05-11).

Do not use a flexible ball

type hone to recondition
the rod bearing bore. The rod bearing bore is shot
peened and stress relieved. Honing degrades the
bearing seat by removing the shot peened finish.
Disregarding this information could result in product damage.

12. Repeat measurements on other side of rod bearing

bore (see Figure 3.05-29).
13. Discard connecting rod if variation between four
out-of-round measurements on either side of bore
exceeds 0.001 in. (0.0254 mm).

WEIGHT
CLASSIFICATION
STAMP

11. Using an inside micrometer or dial bore gauge,

measure diameter of one side of connecting rod bearing
bore at four locations (see Figure 3.05-29). Write down
diameter readings for reference purposes. Difference
between largest and smallest diameter is out-of-round
condition.

Figure 3.05-30. Weight Classification Stamp Location

Never intermix rods of

different weight classifications. Disregarding this information could result
in product damage.
Table 3.05-11. Connecting Rod Weight Classifications
A205507A SERIES
Weight
Class
A
B
C
Weight
Class
A
B
C

Figure 3.05-29. Check Rod Bearing Bore For

Out-Of-Round And Taper

FORM 6296 First Edition

Large End
Weight
0.06 lb.
42.5 lb.
43.5 lb.
44.5 lb.

Small End
Weight
0.06 lbs.
20.0 lb.
21.0 lb.
22.0 lb.

Total Rod
Weight
0.13 lbs.
62.5 lb.
64.5 lb.
66.5 lb.

Large End
Weight
0.06 lb.
40.3 lb.
41.3 lb.
42.3 lb.

Small End
Weight
0.06 lb.
19.7 lb.
20.7 lb.
21.7 lb.

Total Rod
Weight
0.12 lb.
60 lb.
62 lb.
64 lb.

A205507C SERIES

NOTE: Total weight is not the most important consideration in matching connecting rods. Connecting rods are
classified by matching unbalanced weight distribution.

3.05 - 29

CRANKCASE COMPONENT OVERHAUL

Carefully inspect new
connecting rods before
use. Damage may occur from careless handling.
Verify that the rod shank is free of sharp nicks,
dents, gouges, etc.

OIL
GROOVES

All grinding to remove damages must be longitudinal

and blend smoothly with the surrounding areas. Do not
transverse grind.
1. Rotate one bushing and find split line (use new piston
pin bushing) (see Figure 3.05-31).
BUSHING

SPLIT LINE

SPLIT LINE

1/8 in. PLUG

Figure 3.05-33. Verify Orientation Of Rod Pin

Bushings Oil Groove

Figure 3.05-31. Rod Pin Bushing

2. Position bushing over rod pin bore. Split line should
be 45 degrees off rod centerline with open ends of two
lateral oil grooves facing inward (see Figure 3.05-32
and Figure 3.05-33).
SPLIT LINE OF BUSHING
(NEAR SIDE)

4. Turn connecting rod over and repeat Steps 2 and 3 to

install second bushing.
5. Bushings should have oil grooves at bottom of bore
with closed end of each groove pointing to opposite
sides of rod shank (see Figure 3.05-33). Outside edge
of each bushing must be flush with connecting rod.

Clamp the connecting

rod in a suitable fixture
that references off the center of the crankshaft bore.
A loose boring setup will produce an oblong hole.
Disregarding this information could result in product damage.
Do not ream the upper
connecting rod bushings. The reamer will merely follow the existing
bushing bore. Diamond bore the bushings to
maintain rod centerline tolerances. Disregarding
this information could result in product damage.

45

SPLIT LINE OF
BUSHING (FAR SIDE)

Figure 3.05-32. Align Rod Pin Bushing Split Line

3.05 - 30

3. Press piston pin bushing into rod pin bore (see

Figure 3.05-33).

6. Use diamond bore upper connecting rod bushings

(see B in Table 3.05-10) to a diameter of 3.0015 -3.0020 in. (76.238 -- 76.508 mm) and a RMS 24 MAX
finish.
FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
7. Direct compressed air into oil drillings and around
surface of bushings to remove all metal debris.
8. Lightly oil a good piston pin and insert it into upper
connecting rod bore to feel for proper interference fit. Pin
should slide in and out of pin bushing without binding,
but also without pivoting or rocking.

3. Position fully grooved bearing above bearing seat on

rod cap. Shell diameter is slightly larger than connecting
rod bore, so bearing ends protrude approximately
1/4 in. (6.35 mm) above bearing seat (see
Figure 3.05-35).

FULLY GROOVED
(NO OIL HOLES)

9. Apply a drop of Loctite! 271 Adhesive Sealant (High

Strength) to threads of pipe plug. Install a new 1/8 in.
allen head pipe plug in oil hole above pin bore (see
Figure 3.05-33).
10. Wedge a pointed punch between plug and connecting rod threads. Strike punch sharply with a single blow.
Staking distorts threads of plug and locks it in place.

TANG LOCATED AT
BEARING EDGE

ROD CAP
(LOWER)

TANG LOCATED AT
BEARING CENTER

ROD BLADE
(UPPER)

11. Place a second stake 180 degrees from first.

12. Remove any metal chips or fragments that may
have been produced by staking operation.

UNGROOVED
OIL HOLES

CONNECTING ROD BEARING RUNNING

CLEARANCE
1. Obtain a set of new connecting rod bearings. Each
set consists of two different shells.

NOTE: The rod cap bearing (lower) is fully grooved with

no oil holes and has a tang located on the bearing edge.
The rod bearing (upper) is ungrooved with two oil holes
and has a tang located at the bearing center (see
Figure 3.05-34).

Figure 3.05-34. Connecting Rod Bearings

PARTING EDGES

Do not touch the rod

bearing running surface.
Acidic skin secretions promote the start of surface
corrosion and wear in the affected area.
The bearing shells and
rod bore must be completely free of oil, dirt or other foreign material. Any
dirt or debris caught between the bearing shell and
bore results in bearing distortion and reduced
service life.

Figure 3.05-35. Bearing Shell

2. Wipe rod bearing bore and bearing clean.

FORM 6296 First Edition

3.05 - 31

CRANKCASE COMPONENT OVERHAUL

4. Apply even pressure on edges of bearing and press
into place. Locating tang on edge of bearing must fit
squarely in notch machined in roll pin side of cap (see
Figure 3.05-36).

9. Tighten four connecting rod capscrews in proper

numerical sequence, as follows:
A. Lubricate threads and under heads of four
ferryhead connecting rod capscrews with
SAE 30 engine oil.

ROLL PIN

NOTCH

B. Locate number 1 stamped in connecting rod

cap. Hand tighten a capscrew in this hole first.
Hand tighten remaining capscrews in positions 2
through 4 (see Figure 3.05-37).

TANG

C. Following same numerical sequence, tighten

capscrews to 50% of final value.
D. Repeat sequence, tighten capscrews to
180 -- 190 ft-lb (244 -- 257 N m).
ROD CAP
STAMP

5. Position partially grooved bearing above bearing

seat on rod. Centered tang must be directly above
notch. Apply even pressure on edges of bearing and
press it into place.

ROD CAP

6. Verify oil holes in bearing align with supply holes in

rod.

7. Verify bearings fit tightly in rod bore.

Both the connecting rods and rod caps are marked

to identify their location in the engine. For example,
12 cylinder rods are stamped 1R, 1L, 2R, 2L, etc. The
rod and cap also have mating numbers. Do not mix
connecting rods and caps. Disregarding this information could result in severe personal injury or
death.
8. Install connecting rod caps. Verify rod and cap are
marked with same number (see Figure 3.05-38).

3.05 - 32

Figure 3.05-36. Bearing Shell

If the bearing shells fit

loosely in the rod bearing
bore, excessive temperatures will occur and shorten bearing service life. A spun bearing may damage
the crankshaft journal.

Figure 3.05-37. Tightening Sequence

10. Measure inside diameter of connecting rod bearing

bore (use an inside micrometer).
11. Measure outside diameter of crankshaft connecting
rod journal (use an outside micrometer).
12. Subtract results of Step 11 from Step 10 to
determine connecting rod bearing running clearance. If
clearance exceeds specification, rod must be replaced.
!

8-1/2 Inch Bore -- L5774, L5794

9-3/8 Inch Bore -- L7044

0.0042 -- 0.0081I (0.10668 -- 0.20574 mm)

0.0042 -- 0.0081I (0.10668 -- 0.20574 mm)

13. Remove caps from connecting rods.

14. Cover connecting rods and caps with a clean plastic
sheet to protect them from dust and dirt.

FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

CYLINDER
LOCATION

CAP AND BLADE

MATCH NUMBERS
WEIGHT CLASSIFICATION
A, B, OR C

Figure 3.05-38. Keep Connecting Rod Caps And Blades Properly Mated

CONNECTING ROD BEARING RUNNING CLEARANCE MEASUREMENT WITH PLASTIGAGE

Plastigaget provides an easy and accurate way to

check rod bearing running clearances. Plastigaget is a
special plastic thread with extremely accurate crush
properties.
1. Remove connecting rod cap. Wipe all oil from
bearing shell and crankshaft journal, if necessary.
2. Place a string of Plastigaget across full width of
bearing shell (parallel to crankshaft) about 1/4 in. off
center line.
3. Install rod cap. Tighten connecting rod capscrews to
specified torque.
4. Remove bearing cap without rotating crankshaft.
Flattened Plastigaget will be found adhering to rod
bearing shell or crankshaft journal.

CYLINDER LINER

CYLINDER LINER DISASSEMBLY

Cylinder liner weighs approximately 63 lb. (28 kg).
Use a suitable lifting device and exercise caution
during removal or installation to prevent severe
personal injury or death.
1. Remove lower, middle and upper O-rings from
cylinder liner (see Figure 3.05-39).

Do not use a cylinder

liner gasket.. Using the
liner gasket will cause the liner to project too far
above the crankcase deck for proper head gasket
sealing, causing severe engine damage.

5. Compare width of Plastigaget strip with graduated

scale on envelope. Scale indicates bearing running
clearance in thousandths of an inch (or millimeters).

NOTE: Measure both ends of the Plastigage strip. If

the bearing bore or crankshaft journal is tapered, then
one end of the flattened Plastigage strip will be wider
than the other.
6. Remove Plastigaget material from engine and
discard.
FORM 6296 First Edition

3.05 - 33

CRANKCASE COMPONENT OVERHAUL

1. To remove oily residues, apply Magnafluxt Spotcheck Cleaner/Remover (SKC-S) directly to test area.
Thoroughly wipe area with a clean cloth. Repeat
procedure as necessary. Final wiping should result in a
clean cloth. Allow test area to dry.
NOTE: Wear rubber gloves to avoid hard-to-remove
stains on hands.
2. Spray test area with Magnafluxt Spotcheck Penetrant (SKL-SP). Wait 1 to 30 minutes.
3. Spray Magnafluxt Spotcheck Cleaner/Remover
(SKC-S) on a clean cloth (not on test area). Wiping in
one direction, remove all surface penetrant. Repeat as
necessary.
UPPER AND
MIDDLE O-RINGS

4. Spray test area with Magnafluxt Spotcheck Developer (SKD-S2). Apply a thin even film. Allow film to dry
completely. Proper application dries to an even white
layer.

LOWER O-RING

5. Carefully inspect test area for cracks. A bright

colored solid or dotted line marks a crack. Fine cracks
may take up to 15 minutes to appear. Large cracks can
be seen almost immediately. If crack is wide and deep,
indication will grow and spread.

Figure 3.05-39. Cylinder Liner

CYLINDER LINER CLEANING AND INSPECTION

Cylinder Liner Cleaning
1. Thoroughly clean cylinder liner.

Compressed air can pierce the skin and cause

severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
2. Hot rinse liners and dry with moisture free compressed air.

Cylinder Liner Magnaflux Application

Always carefully read the manufacturers instructions to avoid severe personal injury or death.
Using the Magnafluxt Dye Penetrant Test Kit (Tool
P/N 494283), inspect the liners for surface cracks. Pay
particular attention to the area in or around the three
liner seal grooves and beneath the upper liner flange.
3.05 - 34

6. Wipe test area clean if cracks are not found.

Thoroughly wash liner to remove any traces of dye
penetrant.

Cylinder Liner Cleaning

1. Inspect cylinder liner bore for defects or damage in
ring travel area. Replace liners that are severely scored,
scuffed or scratched.
2. Inspect outside surfaces of cylinder liner for corrosion and cavitation damage. Pay particular attention to
upper liner flange and lower liner seal areas. Replace
liners that are severely pitted.
3. Using an inside micrometer or dial bore gauge, check
for excessive liner bore wear and taper (see
Table 3.05-2).

Waukesha assumes
absolutely no liability for
any damage that may occur through the reuse of
engine parts falling within published wear limit
guidelines. Reuse of engine parts that do not meet
the new part specifications listed in Section 1.20
Specifications of this manual are the sole
responsibility of the user. Under no circumstances
is the reuse of any part exceeding the published
wear limits justified.

FORM 6296 First Edition

CRANKCASE COMPONENT OVERHAUL

Use the published wear
limits with discretion. Although Waukesha recognizes that many used parts
are suitable for continued service, there is almost
always a corresponding reduction in performance.
Carefully consider the following items before reusing any particular part: (a.)The number of mating
parts being reused. (b.) The extent of the repair
relative to the expected service life prior to the next
major overhaul. (c.) The engine application, such as
horsepower requirement, maintenance intervals
and type of installation. (d.) The problems that may
occur through reuse.
Maximum liner wear
occurs at the very top of
top ring travel. Minimum wear occurs below ring
travel. Failure to measure the liner diameter at
these points may result in a faulty decision
regarding the suitability of the liner for continued
use.
4. At top of piston ring travel area (just below cylinder
ridge), measure cylinder liner diameter at two locationsparallel and perpendicular to crankshaft. Mark readings
on outside of cylinder liner for reference purposes.
5. Repeat procedure below piston ring travel area at
bottom of the bore.

2. Use a flexible ball-type deglazing tool (see

Figure 3.05-40), (8-1/2 in. bore -- Tool P/N 494236;
9-3/8 in. bore -- Tool P/N 494234). A bristle tip or
finishing stone arrangement (180 to 250 grit) is able to
produce a 60 degree cross hatch pattern (see
Figure 3.05-41). A 60 degree cross hatch pattern
ensures an even flow of oil onto cylinder walls and
promotes longer liner, piston and ring life.

Figure 3.05-40. Flexible Hone

60"

6. Refer to Table 3.05-2 for new part tolerances of

cylinder liner bore. Discard cylinder liner if any single
measurement is not within allowable limits.

NOTE: Check piston to liner clearance for each individual piston and liner pair that will be used on the engine.
7. Measure piston skirt to cylinder liner clearance for
each paired piston and liner (see Table 3.05-2).
CYLINDER LINER DEGLAZING

Cylinder liner honing is

not recommended as a
liner reconditioning method. Disregarding this information could result in product damage and/or
personal injury.
Deglaze the cylinder liner bore. Deglazing removes
wear patterns, minor scuff marks and scratches without
enlarging the liner bore diameter.
1. Coat liner bore with clean engine oil (use a cloth).

A uni-directional honing
pattern does not provide
optimum lubrication and may result in severe piston
scuffing.
FORM 6296 First Edition

Figure 3.05-41. Cylinder Liner Deglazing

3.05 - 35

CRANKCASE COMPONENT OVERHAUL

3. Install deglazing tool in a slow-speed drill. The speed
at which tool rotates determines the speed at which it
must be stroked up and down bore to produce desired
cross hatch pattern.
4. Move deglazing tool up and down the entire length of
the liner bore for 10 to 12 complete strokes.

NOTE: Make the transition between the naturally worn

surface and the area cut with the ridge reamer as
smooth as possible.
5. Stop to examine liner bore and/or take measurements. A precise cross hatch pattern in the piston travel
area is the most important.

Failure to remove all

abrasive particles may
result in premature liner, piston and ring wear and
possible engine failure.

6. Thoroughly wash cylinder liner bore with liquid

dishwashing soap and warm water to remove all
abrasive particles and residual grit. Continue cleaning
until a clean cloth shows no evidence of dirt or debris.

FLYWHEEL

RING GEAR REMOVAL

Always wear protective equipment when installing
or removing components with an interference fit.
Installation or removal of interference components
may cause flying debris. Failure to use protective
equipment may result in severe personal injury or
death.
Do not try to pry or tap
the ring gear from the
flywheel. The shrink fit holds the ring gear with
sufficient bond that damage to the gear will result if
these methods are used.
When cutting the ring
gear from the flywheel,
use caution to avoid damage to the flywheel.
1. Cut into ring gear between two teeth (use hacksaw)
(see Figure 3.05-42).

Compressed air can pierce the skin and cause

severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
7. Hot rinse liner and dry with moisture free compressed air.
8. Oil inside of cylinder liner with a light coat of clean
engine oil.

RING GEAR

9. Cover cylinder liners with a clean plastic sheet to

protect them from dust and dirt.

BLOCKS

FLYWHEEL

Figure 3.05-42. Flywheel Ring Gear

2. Wedge cold chisel into cut and tap chisel until ring
gear slits open.
3. Clean outer circumference of flywheel to ensure a
good fit for ring gear. Dress down any burrs or raised
spots.

3.05 - 36

FORM 6296 First Edition