Mercury 2L2Z-6108-GA Piston And Pin Assembly

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a) Keep the back sides of the bearing inserts and the insides of the connecting rods and caps perfectly clean. b) Ensure the correct piston/rod assembly for each cylinder. c) The notches or mark on the piston must face the FRONT of the engine. d) Lubricate the cylinder walls with clean oil. e) Lubricate the bearing faces when installing the rod caps after the oil clearance has been checked.

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

If the pistons must be removed from the connecting rods for any reason, they should be taken to an automotive machine shop. While there, have the connecting rods checked for bend and twist. Note: Unless new pistons or connecting rods must be installed, do not disassemble the pistons and connecting rods.

Slip a section of plastic or rubber hose over each connecting rod bolt. Note that 4.6L engines use cap bolts that are screwed into the rod after the rod and cap are assembled on the crankshaft.

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

Before the connecting rods are removed, check the endplay with a dial indicator or with feeler gauges. Slide them between the first connecting rod and the crankshaft throw until the play is removed. The endplay is equal to the thickness of the feeler gauge(s).

Gently tap on the top of the piston with the end of a wooden hammer handle while guiding the end of the connecting rod into place on the crankshaft journal. Keep some downward pressure on the ring compressor.

The piston/connecting rod assemblies must be cleaned, and the original piston rings removed from the pistons. It is important to always use new piston rings when the engine is reassembled.

The "fractured cap method" is a new manufacturing technique where the cap is fractured from the rod to ensure a perfect match upon reassembly. This means that no caps are interchangeable.