ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-054   Piston and Connecting Rod Assembly

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• Drain the coolant. Refer to Procedure 008-018 in Section 8.
• Remove the lubricating oil pan. Refer to Procedure 007-025 in Section 7.
• Remove the lubricating oil suction tube. Refer to Procedure 007-035 in Section 7.
• Remove the piston cooling nozzles, if required. Refer to Procedure 001-046 in Section 1.
• Remove the cylinder head. Refer to Procedure 002-004 in Section 2.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Rotate the crankshaft until the pistons are just below the carbon deposits that are found above the ring travel area.

Use an abrasive pad, Part Number 3823258 or equivalent, and solvent to remove the carbon deposits.

Mark each piston according to the cylinder location.

NOTE: On pistons with anodized coatings, do not stamp on the anodized coating or on the outer rim. Do not stamp on the aluminum piston crown above the piston pin axis.

Rotate the crankshaft to position the rod cap at Bottom Dead Center (BDC) for removal.

Mark each connecting rod and rod cap according to the cylinder number location.

Engines with Horizontal Split Connecting Rods

Remove the nuts, connecting rod cap, and lower connecting rod bearing.

Mark the cylinder number and the letter “L” (lower) on the flat surface of the bearing tang.

Push the connecting rod and piston assembly out of the cylinder bore. Care must be taken to not damage the connecting rod or bearing.

Remove the upper rod bearing.

Mark the cylinder number and the letter “U” (upper) on the flat surface of the bearing tang.

Use both hands to remove the piston and connecting rod assembly.

If parts are reused, the piston and connecting rod assemblies must be installed in the same cylinder locations from which they were removed to provide the proper fit of worn mating surfaces.

Use tags to mark the piston and connecting rod assembly locations as they are removed.

Place the rod and piston assemblies in a container to protect them from damage.

Engines with Angle Split Connecting Rods

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

Rotate the crankshaft until the pistons are just below the carbon deposits that are found above the ring travel area.

Use an abrasive pad, Part Number 3823258 or equivalent, and solvent to remove the carbon deposits.

Mark each piston according to the cylinder location.

NOTE: On pistons with anodized coatings, do not stamp on the anodized coating or on the outer rim. Do not stamp on the aluminum piston crown above the piston pin axis.

Rotate the crankshaft to position the rod caps at BDC for removal.

Mark each connecting rod and rod cap according to the cylinder location.

Loosen the connecting rod capscrews.

NOTE: Do not remove the capscrews from the rods at this time.

Use a rubber hammer to hit the connecting rod capscrews to loosen the caps from the dowels.

CAUTION  Do not damage the fractured split surface on the connecting rod or connecting rod cap while the connecting rod caps are removed. If the fractured split surface is damaged, the connecting rod and connecting rod cap must be replaced to help reduce the possibility of engine damage. Incorrect assembly can damage the rod.

Remove the connecting rod capscrews.

Remove the rod cap.

Remove the lower rod bearing.

Mark the cylinder number and the letter “L” (lower) on the flat surface of the bearing tang.

Push the connecting rod and piston assembly out of the cylinder bore. Care must be taken to not damage the connecting rod or bearing.

Remove the upper rod bearing.

Mark the cylinder number and the letter “U” (upper) on the flat surface of the bearing tang.

Use both hands to remove the piston and connecting rod assembly.

If parts are reused, the piston and connecting rod assemblies must be installed in the same cylinder location from which they were removed, to provide the proper fit of worn mating surfaces.

Use tags to mark the piston and connecting rod assembly locations as they are removed.

Place the rod and piston assemblies in a container to protect them from damage.

Use piston ring expander, Part Number 3823137, to remove the piston rings.

Use internal snap ring pliers to remove the snap rings from both sides of the piston.

Remove the piston pin.

NOTE: Heating the piston is not required.

NOTE: When the piston pin is removed from an articulated piston, the skirt will separate from the crown. Use care to prevent damage to the piston.

Mark the number of the cylinder from which the piston, crown, skirt, and pin were removed, on the parts, to make sure they are installed in the correct cylinder location, if they are to be reused.

Clean the pistons. Refer to Procedure 001-043 in Section 1.

Inspect the pistons. Refer to Procedure 001-043 in Section 1.

Inspect the connecting rods. Refer to Procedure 001-014 in Section 1.

Install the retaining ring in the pin groove on one side of the piston.

Lubricate the pin and pin bores with engine lubricating oil.

CAUTION  Make sure the “front” marking on the piston and the numbers on the rod and cap are oriented as illustrated.

Align the pin bore of the rod with the pin bore of the piston skirt, and install the piston pin.

Install the second retaining ring.

CAUTION  Most piston rings look similar but have significant difference. Make sure the correct part number is being used for the engine.

The top surface of the upper and intermediate rings are identified either with the word “TOP” or a supplier identification mark, such as a dot. Assemble with the word “TOP” or the supplier mark facing upward.

The bottom, or oil control ring, can be installed with either side up.

NOTE: The two-piece oil control ring must be installed with the expander ring gap 180-degrees from the gap of the oil ring.

Use piston ring expander, Part Number 3823137, to install the rings on the piston.

Position the oil ring expander in the oil control ring groove.

NOTE: If the pistons are being reused, the crown, skirt, and pin must be matched as they were when they were removed.

Position the skirt over the piston crown.

NOTE: It is not necessary to heat the articulated pistons before assembly. The piston pin is a slip fit.

Install the retaining ring in the pin groove on one side of the piston.

NOTE: If the pistons are being reused, the crown, skirt, and pin must be matched as they were when they were removed.

Position the skirt over the piston crown.

NOTE: It is not necessary to heat the articulated pistons before assembly. The piston pin is slip fit.

Engines with Angle Split Connecting Rods

Install the retaining ring in the pin groove on one side of the piston.

CAUTION  Do not use a hammer to install the piston pin. The piston can distort, causing it to seize in the liner.

CAUTION  The lock tang on the connecting rod must be on the side opposite the deep valve pocket of the piston crown.

Lubricate the pin and pin bores with engine lubricating oil.

Align the pin bore of the rod with the pin bore of the piston skirt and crown, and install the piston pin.

CAUTION  The snap ring must be seated completely in the piston groove to prevent engine damage during engine operation.

Install the second retaining ring.

CAUTION  Most piston rings look similar but have significant difference. Make sure the correct part number is being used for the engine.

The top surface of the upper and intermediate rings are identified either with the word “TOP” or a supplier identification mark, such as a dot. Assemble with the word “TOP” or the supplier mark facing upward.

The bottom, or oil control ring, can be installed with either side up.

NOTE: The two-piece oil control ring must be installed with the expander ring gap 180-degrees from the gap of the oil ring.

Use piston ring expander, Part Number 3823137, to install the rings on the piston.

Position the oil ring expander in the oil control ring groove.

The cylinder block and all parts must be clean before assembly. Inspect the cylinder liners for reuse.

Refer to Procedure 001-028 in Section 1.

Use a clean, lint-free cloth to clean the connecting rods and bearing shells.

If new bearings are not used, the used bearings must be installed on the same connecting rod and location from where they were removed.

Install the upper bearing shell into the connecting rod.

The tang of the bearing shell must be in the slot of the rod. The end of the bearing shell must be even with the cap mounting surface.

NOTE: The upper and lower rod bearing shells are not interchangeable on angle split connecting rods. The backs of the bearings are marked with either “UPR” or “LWR” to indicate their location.

NOTE: If the connecting rod bushing is removed for any reason, a new bushing must be used.

Use assembly lubricant, Part Number 3163087, or equivalent, to coat the inside circumference of the bearing shell.

Apply a film of clean 15W-40 oil to the cylinder liner.

Lubricate the rings and piston skirts with clean engine lubricating oil.

Rotate the rings to position the ring gaps as shown.

NOTE: The ring gap of each ring must not be aligned with the piston pin, or with any other ring. If the ring gaps are not aligned correctly, the rings will not seal properly.

Use piston ring compressor, Part Number 3823290, to compress the rings.

Rotate the crankshaft so the connecting rod journal of the connecting rod being installed is at BDC.

CAUTION  Failure to follow this step will result in extensive engine damage.

Engines with Angle Split Connecting Rods

NOTE: For all piston types make sure that the “FRONT” marking on the piston crown is pointed toward the front of the engine block.

Align the piston crown deep valve pocket on the exhaust side of the engine.

Insert the connecting rod through the cylinder liner until the ring compressor contacts the top of the liner.

The angle split of the connecting rod should face the intake side.

Hold the ring compressor against the cylinder liner.

Push the piston through the ring compressor and into the cylinder liner.

Push the piston until the top ring is completely in the cylinder liner.

NOTE: If the piston does not move freely, remove the piston and inspect for broken or damaged rings.

Carefully push the piston into the bore while guiding the connecting rod to the crankshaft journal.

NOTE: Connecting rod guide, Part Number 3824476, can be used to aid installation on engines with connecting rod studs.

NOTE: If new bearings are not used, the used bearings must be installed on the same connecting rod cap from which they were removed.

Install the bearing in the connecting rod cap.

The tang of the bearing (2) must be in the slot of the cap (1).

Use assembly lubricant, Part Number 3163087, or equivalent, to coat the inside diameter of the bearing shell.

Use clean 15W-40 oil to lubricate the connecting rod capscrew threads.

CAUTION  Do not damage the fractured split surface on the connecting rod or connecting rod cap while the connecting rod cap is removed. If the fractured split surface is damaged, the connecting rod and connecting rod cap must be replaced to help reduce the possibility of engine damage.

The connecting rod and cap must have the same number and must be installed in the proper cylinder. The connecting rod cap number and rod number must be on the same side of the connecting rod to prevent engine damage during engine operation.

Engines With Connecting Rod Studs and Nuts

Install the connecting rod cap and nuts.

Engines With Connecting Rod Capscrews

Install the connecting rod cap and capscrews.

Use a marked socket and torque wrench to tighten the rod capscrews or nuts.

Use the torque plus angle method to tighten the connecting rod capscrews or nuts in alternating sequence.

NOTE: Do not measure the clearance between the rod cap and crankshaft.

Measure the side clearance between the connecting rod and crankshaft.

Connecting Rod and Crankshaft Side Clearance

Check for freedom of rotation as the connecting rod caps are installed. If the crankshaft does not rotate freely, check the installation of the connecting rod bearings and the bearing size.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the piston cooling nozzles, if required. Refer to Procedure 001-046 in Section 1.
• Install the lubricating oil suction tube. Refer to Procedure 007-035 in Section 7.
• Install the lubricating oil pan. Refer to Procedure 007-025 in Section 7.
• Install the cylinder head. Refer to Procedure 002-004 in Section 2.
• Fill the engine with lubricating oil. Refer to Procedure 007-037 in Section 7.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.