159232-0401 ZEXEL 9 421 610 784 BOSCH PLATE 9421610784 1592320401 1157298090

Start By:a. remove cylinder head assemblyb. remove engine balancer group (3114 Engines)c. remove oil pump (3116 Engines)d. remove piston cooling tubes 1. Check the connecting rods and caps for their identification and location in the engine. The connecting rods are to be marked (only by etching) with the number of the cylinder in which they are used. Rods and caps are to be marked on the same side of the rod in relation to the bearing retainer notch.2. Remove rod cap nuts (1) and rod bearing cap (2) from the connecting rod. Remove the lower half of the bearing from the rod bearing cap.
To protect the crankshaft from the threaded portion of the connecting rod bolts, cut short pieces of rubber hose, and install them over the threaded portion of the bolts as shown in Photo C20235P1.
3. Carefully remove the piston and connecting rod from the cylinder block. Remove the upper half of the bearing from the connecting rod.4. Remove the remainder of the pistons and connecting rods as in Steps 1 through 3. The following steps are for the installation of the pistons and connecting rod assemblies. 5. Position the piston ring end gaps 120 degrees apart. Install Tool (A) on the piston as shown.6. Be sure the short pieces of rubber hose are installed on the connecting rod bolts. Install the connecting rod and piston group with the rod forging part number facing to the rear of the engine. The rear of the engine is the flywheel end. Thoroughly lubricate the piston crown, piston skirt and the cylinder bore with clean engine oil just prior to installation of the piston group in the cylinder block.7. With the number one crankshaft throw at bottom center, carefully install the piston and connecting rod assembly in the cylinder block. 8. Put the connecting rod in alignment with the crankshaft. Using a rubber mallet, tap the piston into the cylinder bore until Tool (A) comes off of the piston.9. Before the connecting rod comes in contact with the crankshaft, install the upper half of the rod bearing. Be sure the bearing tab engages with the groove in the connecting rod.10. Apply clean engine oil on the upper rod bearing. Continue tapping the piston down, guiding the connecting rod onto the crankshaft.11. Position the lower half of the rod bearing in the corresponding numbered rod bearing cap. Be sure the bearing tab engages with the groove in the rod bearing cap.13. Put clean engine oil on the lower rod bearing surface. Install the rod bearing cap on the connecting rod with the number on the bearing cap on the same side and same number as on the connecting rod.14. Tighten the connecting rod bolts as follows: a. Put clean engine oil on the bolt threads, and all surfaces that make contact between the bolts and cap.b. Tighten