Onan DJA Series User Manual

A859 II
HEAVIEST COMPRESSION
RING IN TOP GROOVE
COMPRESSION RINGS
r-OIL CONTROL RING -i
RAIL
-RAIL
"EXPANDER
CONNECTING ROD
BUSHINGS—
BUSHING ENDS MUST
BE FLUSH WITH SIDES
OF ROD TO PERMIT
1/16" OIL GROOVE
BETWEEN BUSHINGS
PRECISION TYPE
BEARING CROSS-SECTION
MEASURE CLEARANCE IN
DIRECTION INDICATED BY
ARROW
A88I
FIGURE 44. PISTON RINGS
FIGURE 45. CONNECTING ROD BUSHINGS
Connecting Rods: Clean the connecting rod and check
for defects. Check the connecting rod bushings for
proper clearance with the piston pin. Clearance should
be .0002"to .0007".
If the bushings are excessively worn, press them out
and install one new bushing from each side of the
bushing bore. Press the new bushings only until flush
with the side of the rod to leave 1/16" to 7/64" oil
groove in the center. See Figure 45.
Connecting Rod Bearings: Inspect the connecting rod
bearings for burrs, breaks, pits and wear. Measure the
clearance between bearings and the crankshaft journal.
The clearance should be 0.001-inch or 0.003-inch. If
necessary, replace with new standard or oversize pre-
cision bearings.
Assembly and Installation:
1. Install the connecting rod on the piston with the
pin and retaining rings. If new bushings were
installed, check to see that the ends are flush
with the connecting rod to provide for the oil
recess in the center.
2. Install the rings on the piston. Tapered rings will
be marked top or identified in some other manner.
Place this mark toward the closed end of the
piston. Space the ring gaps 1/4 gap of the way
around the piston from one another. No gap should
be in line' with the piston pin. Oil the rings and
piston.
3. Position a bearing half in the connecting rod. Be
sure there is no dirt under the bearing. This could
cause high spots and early bearing failure.
4. Oil the cylinder wall. Install the piston in the
cylinder using a suitable installer. The assembly
should be installed with the stamp on the piston
in the same direction as when removed.
5. Position the connecting rod on the camshaft, oil
the journal and install its rod cap with bearing
half. When installing the rod cap, position so the
raised witness mark on the forging matches the
mark on the connecting rod (Figure 46).
CRANKSHAFT
BE SURE THAT CONNECTING
ROD WITNESS MARKS ARE
ALIGNED
FIGURE 46. CONNECTING ROD CAP
40

Onan DJA Series Specifications

General

Brand	Onan
Model	DJA Series
Category	Engine
Language	English