2. Insert the liners into their places in the connecting rods and caps. Make sure the mounting tabs fit into the slots in the cranks (see illustration).
20.2. The tongue on the bearing shell must fit into the recess in the connecting rod.
C- and E-series engines
Checking the connecting rod bearing operating clearance
3. Lay out the four sleeves in the order they will be installed, with the working surface facing down. Install pre-selected seals into the base of each cylinder liner (see illustration).
20.3. Install the lower cylinder liner O-ring (e-series engine).
4. Lubricate the pistons and piston rings, then place each piston/connecting rod assembly next to its corresponding liner.
5. Begin assembly with piston #1, first checking that the piston ring cuts are evenly spaced (120° apart). Compress the piston rings with a special tool.
6. Insert the piston/connecting rod assembly into the base of the cylinder bore. Make sure the arrow on the piston head points towards the flywheel/drive plate. Using a block or hammer handle, drive the piston into the sleeve until the piston head is approximately 25 mm from the top of the sleeve.
20.6. The arrow on the piston head must point towards the flywheel.
7. Repeat the procedure with the remaining three piston and liner assemblies.
8. Turn the crankshaft so that connecting rod journal No. 1 is at bottom dead center.
9. With the liner O-ring in place, place the liner with the piston/connecting rod assembly into the cylinder block. The arrow on the piston head must point towards the flywheel/drive plate.
10. To measure the connecting rod bearing operating clearance, see. information in Chapter 19.
11. After installing the sleeve/piston assembly, secure the sleeve with a bolt and washer, or a clamp (see illustration).
20.11. Fixing cylinder liners using clamps.
12. Repeat the above procedures with the remaining assemblies.
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Final installation
13. After checking the running clearance of all crankpins, wash off all traces of Plastigauge from the bearings and crankpins.
14. Generously lubricate the crankshaft journals and connecting rod bearings. Install the bearing caps. Tighten the cover nuts/bolts to the specified tightening torque Specifications, check how the crankshaft turns every time. Finally, make sure that all the sleeves are correctly positioned relative to each other (a 0.1 mm thick feeler gauge should be able to pass freely through the gaps between them) (see illustration).
20.14. Check the gap between the sleeves.
If this is not the case, it may be necessary to swap one or more piston/liner assemblies to achieve this clearance.
D- and F-series engines
Checking the connecting rod bearing operating clearance
15. Lubricate piston No. 1 and rings, making sure that the ring cuts are evenly spaced from each other (120°).
16. Install the compressor onto piston #1, then insert the piston and connecting rod into cylinder #1. With the crankshaft journal at bottom dead center, carefully insert the piston into the cylinder while simultaneously guiding the connecting rod onto the crankshaft journal (see illustration).
20.16 Using a wooden hammer handle, carefully tap the piston into the cylinder - D-series engine shown.
Make sure the arrow on the piston head surfaces points towards the flywheel.
17. To measure the connecting rod bearing operating clearance, see. information in Chapter 19.
18. Repeat the above procedures with the remaining piston/connecting rod assemblies.
Final installation
19. After checking the running clearance of all crankpins, wash off all traces of Plastigauge from the bearings and crankpins.
20. Generously lubricate the journals and shells of the connecting rod bearings. Install the bearing caps. Tighten the mounting bolts to the specified tightening torque Specifications, each time checking that the crankshaft turns freely.