Ensure that gaps in the piston rings are staggered 90° apart on the new piston
assembly. Also ensure that the "hook" in the upper piston rings is away from the top of
Coat the piston pin (6), connecting rod bore, and piston pin bore with light oil, MIL-L-
Do not force the piston pin (6) into the piston pin bore; this will damage
the piston (4)
Assemble the connecting rod (7) and piston (4) with piston pin (6) and piston pin retainer
clips (5). Ensure clips (5) are secure in their grooves.
Ensure the connecting rod (7) moves freely.
Coat the crankcase cylinder bore with light oil, MIL-L-2104. Then using a piston ring
compressor, install the piston and connecting rod into the cylinder bore while aligning the
connecting rod with the crankshaft. When aligned properly, the connecting rod cap (3)
should line up with the connecting rod end.
Apply light oil, MIL-L-2104 to the crankshaft rod journal. Then install the connecting rod
cap (3). Install the two Torx head bolts (2) finger tight.
Use a torque wrench to tighten the Torx head bolt closest to the "W" of the cast word
"WABCO" from between 48 and 58 in.-lbs (5.4 to 6.6 Nm). Then torque the other bolt
from between 48 and 58 in.-lbs (5.4 to 6.6 Nm).
Turn the Torx head bolt closest to the "W" an additional 70° (+15/-5°). Then turn the
other bolt an additional 70° (+15/-5°).
Ensure that the crankshaft rotates freely without binding. The maximum torque require
to rotate the crankshaft is 53 in. lbs (6 Nm).
Apply Loctite 648 sealant to the edge of the sump plug (1). Press the plug evenly into
Insert the new head cover gasket and assemble the head and the cover with two new
head cover screws. Install the head assembly with new head gasket and head bolts