G3516E Generator Set GAS00001-UP(SEBP3934 - 31) - Systems & Components Page 1 of 5

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Product: GENERATOR SET

Model: G3516E GENERATOR SET GAS
Configuration: G3516E Generator Set GAS00001-UP

Disassembly and Assembly

G3512E, G3516C and G3516E Generator Set Engines
Media Number -KENR5271-06 Publication Date -01/05/2012 Date Updated -31/05/2012

i05326093

Piston and Connecting Rods - Install

SMCS - 1225-012

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Piston Ring Expander 1
H 1U-7616 Piston Ring Compressor 1
J 334-0519 Grease 1
K 364-2837 (1)
Installer As 1
(1)
For use with 350-0074 Cylinder Liner .

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g00582421

1. Use Tooling (C) to install piston rings (6) on piston (3) .

2. The ends of the oil control piston ring should be 180 degrees away from the oil ring end
gap. The white-colored section of the oil ring spring should also be visible at the oil ring end
gap.

3. Install the intermediate ring with the side that is marked "UP" toward the top of the piston.
Position the intermediate ring with the green strip on the right side of the end gap.

4. Install the top piston ring with the red strip on the right side of the end gap.

5. The piston ring end gaps must be approximately 120 degrees away from each other after
installation.

Illustration 2 g01051820

6. Place clean engine oil on piston pin (4) , the piston pin bearing, and the bore in piston pin
(4) .

7. Position connecting rod (5) in piston (3) and install piston pin (4) .

8. Use Tooling (B) to install the retaining rings that hold piston pin (4) .

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9. Install the upper half of the connecting rod bearing in connecting rod (5) . Ensure that the
tab on the back of the bearing is in the bearing tab groove on connecting rod (5) .

Illustration 3 g02340238

10. Apply clean engine oil to the cylinder liner bore.

11. If necessary, install Tooling (K) in the top of the cylinder liner.

Illustration 4 g01056335

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NOTICE

Improper installation of the piston and connecting rod assembly will

result in severe damage to the engine.

Make sure that the side of the connecting rod bore with the chamfer is
oriented next to the surface of the crankshaft thrust plate. The square
side of the connecting rod bore must be next to the other connecting
rod that is on the same crankshaft journal.

12. Place clean engine oil on the piston rings and the cylinder liner bore. Use Tooling (H) to
compress the piston rings.

13. Install the piston and connecting rod assembly in the engine.

Illustration 5 g00582418

14. Install the lower half of the connecting rod bearing in connecting rod cap (2) . Ensure that
the tab on the back of the bearing is in the bearing tab groove on connecting rod cap (2) .

15. Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing
Clearance - Check" for the correct procedure.

16. Place clean engine oil on the upper half and on the lower half of the connecting rod bearing.

17. Apply Tooling (J) to the threads of the bolts and the threads in connecting rod caps (2) .

18. Position connecting rod cap (2) on the connecting rod and install bolts (1) in connecting rod
cap (2) .

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Illustration 6 g01087388

(12) Side of the connecting rod with the chamfer

(13) Location pin

19. Tighten Bolts (A) and (B) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

20. Tighten Bolts (C) and (D) to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

21. Tighten Bolts (C) and (D) again to a torque of 90 ± 5 N·m (65 ± 4 lb ft).

22. Tighten all of the bolts for an additional 90 ± 5 degrees.

23. Check the side clearance that is between two of the connecting rods that are on the same
journal. The clearance must be 0.85 ± 0.332 mm (0.034 ± 0.0130 inch).

24. Use Tooling (A) to turn the engine in order to access the bolts in the connecting rod cap.

End By:

a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".
b. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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