Tools Required

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the oil pan. Refer to Oil Pan Replacement .
3. Remove the oil pump. Refer to Oil Pump Replacement .
4. Remove the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement .
5. Turn the crankshaft until the piston and rod assembly to be serviced is at Bottom Dead Center (BDC).
6. Lower the engine onto the frame.
7. Lower the vehicle.
8. Remove the engine support fixture.
9. Remove the cylinder head(s). Refer to Cylinder Head Replacement .



10. Use the following procedure in order to remove the ring ridge, as necessary:

10.1.

Turn the crankshaft until the piston is at the bottom of its stroke.

10.2.

Place a cloth on top of the piston.

10.3.

Use the J 24270 in order to remove the piston ring ridge.

10.4.

Turn the crankshaft so that the piston is at the top of its stroke.

10.5.

Remove the cloth and cutting debris.

11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Important: Place matchmarks or numbers on the connecting rod and connecting rod caps. The connecting rod caps must be assembled to their original connecting rod.

12. Remove the connecting rod nuts.
13. Remove the connecting rod cap.
14. Remove the lower connecting rod bearing.




Notice: Install thread protector in order to avoid damage to the crankshaft journal.

15. Install the J 5239 .
16. Push the piston and rod up through the cylinder.
17. Lower the vehicle.



18. Remove the connecting rod, upper connecting rod bearing and piston out of the top of the engine block.
19. Wipe oil from the connecting rod bearings and crankshaft connecting rod journal.
20. Inspect the piston. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect .
21. Inspect the connecting rod bearings. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect .
22. Inspect the connecting rod cap and connecting rod. Refer to Piston, Connecting Rod, and Bearings Clean and Inspect .
23. Inspect the crankshaft connecting rod journal. Refer to Crankshaft and Bearings Clean and Inspect .
24. Protect the crankshaft journals from honing debris.
25. Clean the cylinder bores with a light honing.
26. Clean the cylinder bores with hot water and detergent.
27. Swab the bores with a clean, dry cloth.
28. Swab the bores with new engine oil and a clean, dry cloth.

Tools Required

1. Coat the piston, the piston rings, the cylinder bore, and the bearing surfaces with new engine oil.
2. Install the J 5239 .



3. Compress the piston rings using the J 8037 .



4. When installing the piston and connecting rod assembly, the stamped arrow on the piston must point to the front of the engine while the flange on the connecting rod must face toward the front of the piston on the left hand, and face toward the rear of the piston on the right hand.



5. Install the piston into its original bore using the J 5239 and the J 8037 and lightly tapping the top of the piston with a wooden hammer handle.
6. Firmly hold the J 8037 against the engine block until all of the piston rings have entered the cylinder bore.
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Install the upper connecting rod bearing into the connecting rod.
9. Coat the inside surfaces of the upper connecting rod bearing with new engine oil.
10. Using the J 5239 pull the piston and rod assembly down to the crankshaft.
11. Remove the J 5239 .



12. Install the lower connecting rod bearing into the connecting rod cap.
13. Coat the inside surfaces of the lower connecting rod bearing with new engine oil.
14. Install the connecting rod cap.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Notice: In order to prevent the possibility of rod bolt or bearing cap damage, the bearing caps may need to be tapped into position with a brass or leather mallet before the attaching nuts are installed. Do not use the attaching nuts to pull the bearing caps onto the rod. Failure to observe this information may result in damage to the rod bolt or the bearing cap.

15. Install the connecting rod cap nuts. Refer to Piston, Connecting Rod, and Bearing Installation
16. Inspect the connecting rod for a binding by prying back and forth with a suitable tool. If necessary, loosen and retighten the connecting rod cap.



17. Measure the connecting rod clearance using the following procedure:

17.1.

Install all connecting rod bearings.

17.2.

Lightly tap each connecting rod parallel to the crankpin in order to make sure the connecting rods have clearance.

17.3.

Measure the side clearance between the connecting rod caps using a feeler gage, or dial indicator. Refer to Crankpin (Rod Side Clearance) in Engine Mechanical Specifications for the connecting rod side clearance.

18. Lower the vehicle.
19. Install the cylinder head(s). Refer to Cylinder Head Replacement .
20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
21. Install the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement .
22. Install the oil pump. Refer to Oil Pump Replacement .
23. Install the oil pan. Refer to Oil Pan Replacement .
24. Lower the vehicle.