Mercury 1L2Z-6108-AA Piston And Pin Assembly

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Clean piston/rod assemblies, replace piston rings. Use ring installation tool to extract rings without damaging pistons. Remove carbon deposits from piston tops with wire brush or emery cloth. Clean ring grooves with groove cleaning tool. Inspect pistons for cracks, scoring, scuffing, overheating, or abnormal combustion. Check for piston corrosion indicating coolant leakage. Measure ring side clearance and piston-to-bore clearance. Resize pistons if needed. Inspect connecting rods for cracks or damage, replace if necessary.

The tool should not cut into the ring travel area more than 1/32-inch.

The cylinder walls must be perfectly clean, the top edge of each cylinder must be chamfered, and the crankshaft must be in place.

Ensure the cylinder walls are meticulously clean - Chamfer the top edge of each cylinder - Make sure the crankshaft is in place.

After removal, reassemble the connecting rod caps and bearing inserts in their respective connecting rods and install the cap nuts finger tight. Leaving the old bearing inserts in place until reassembly will help prevent the connecting rod bearing surfaces from being accidentally nicked or gouged.

Carefully inspect each piston for cracks around the skirt, at the pin bosses, and at the ring lands.

Remove the connecting rod cap and bearing insert together. On 4.6L engine connecting rods, the method used to manufacture and machine the rod cap is unique; they "fracture" (break) the cap from the rod to give a perfect match upon reassembly. Don't drop the bearing insert out of the cap.

Clean the connecting rod cap bearing face, remove the protective hoses from the connecting rod bolts, and install the rod cap, ensuring the mating mark on the cap is on the same side as the mark on the connecting rod.

Use a piston ring groove cleaning tool to remove carbon deposits from the ring grooves. If a tool isn't available, a piece broken off the old ring will do the job. Be very careful to remove only the carbon deposits without removing any metal or scratching the sides of the ring grooves.

After removal, reassemble the connecting rod caps and bearing inserts in their respective connecting rods and install the cap nuts finger tight. This helps prevent the connecting rod bearing surfaces from being accidentally nicked or gouged.

Clean the back side of the other bearing insert and install it in the rod cap, ensuring the tab fits into the recess in the cap. Do not apply any lubricant.

If the engine is being rebuilt because of a connecting rod knock, new rods should be installed.

Install the number two (middle) ring with the mark facing up, then use a piston ring installation tool to slip the ring into the middle groove. Repeat the process for the number one (top) ring, ensuring the mark is also facing up.