Mercury 2L2Z-6108-FA Piston And Pin Assembly

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If carbon deposits or cylinder wear have produced ridges, they must be completely removed with a special tool called a ridge reamer. Follow the manufacturer's instructions provided with the tool. Failure to remove the ridges before attempting to remove the piston/connecting rod assemblies may result in piston breakage. Do not let the tool cut into the ring-travel area more than 1/32-inch.

Clean the piston/rod assemblies with solvent and dry them with compressed air (if available). Make sure the oil return holes in the back sides of the ring grooves are clear.

Clean the back side of the other bearing insert, install it in the rod cap, ensure the tab on the bearing fits into the recess in the cap, and do not apply any lubricant. The mating surfaces of the bearing and connecting rod must be perfectly clean and oil-free when assembled.

Check the connecting rods for cracks and other damage. Temporarily remove the rod caps, lift out the old bearing inserts, wipe the rod and cap bearing surfaces clean, and inspect them for nicks, gouges, and scratches. After checking the rods, replace the old bearings, slip the caps into place, and tighten the nuts finger tight. Note: If the engine is being rebuilt because of a connecting rod knock, be sure to install new rods.

The connecting rod endplay must be checked and compared to the Specifications to ensure it's correct. If new rods or a new crankshaft were installed, the endplay may need adjustment.

Piston-to-bore clearance is checked by measuring the bore and the piston diameter. The piston should be measured across the skirt, at a 90-degree angle to, and in line with the piston pin. The clearance is obtained by subtracting the piston diameter from the bore diameter.

If the connecting rod has studs with attaching nuts (rather than cap bolts), slip a short length of plastic or rubber hose over each connecting rod cap bolt to protect the crankshaft journal and cylinder wall as the piston is removed.

Loosen each of the connecting rod cap bolts 1/2-turn at a time until they can be removed by hand.

Cut a piece of Plastigage slightly shorter than the width of the connecting rod bearing, lay it on the number one connecting rod journal, and then install the rod cap with the old bolts.

Rotate the crankshaft several times by hand to check for any obvious binding and check the connecting rod endplay. If new rods or a new crankshaft were installed, the endplay may need to be adjusted.