Tools Required

Important: The coating on the piston allows for an interference fit between the cylinder and the bore. The piston diameter can NOT be measured accurately because the piston coating is not a consistent thickness. Do NOT measure the piston diameter.

1. Inspect the engine block cylinder bore. Refer to Engine Block Cleaning and Inspection .
2. Inspect the piston/connecting rod assembly for damage. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .
3. Use the J 8087 and measure the cylinder bore diameter. Refer to Engine Block Cleaning and Inspection .



4. Measure the J 8087 with a micrometer and record the reading.
5. Compare the cylinder bore measurement to the specifications. Refer to Engine Mechanical Specifications .

5.1.	If the cylinder bore is within specifications, select the original piston or a new, original size piston.

5.2.	If the cylinder bore is not within specifications, select the next oversized piston/connecting rod assembly, then bore and hone the cylinder bore to fit the oversize piston.

1. Coat the following components with clean engine oil:

•	The piston

•	The piston rings

•	The cylinder bore

•	The bearing surfaces




2. Install rubber fuel line onto the connecting rod bolts.




Important: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and cap should face to the front of block on the left bank and to the rear of block on the right bank.

3. Install the piston, connecting rod and upper connecting rod bearing through the top of the engine block.



4. Install the J 8037 onto the piston and compress the piston rings.
5. Use the J 8037 and lightly tap the top of the piston with a wooden hammer handle.
6. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.



7. Use the rubber fuel line in order to guide the connecting rod onto the crankshaft journal.
8. Remove the rubber fuel line.



9. Install the connecting rod cap and lower connecting rod bearing.

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.

Important: When installing the piston/connecting rod assembly, NEW connecting rod nuts must be installed.

10. Install the new connecting rod nuts.

Tighten
Tighten the connecting rod nuts to 30 N·m (22 lb ft) plus an additional 90 degrees.




11. Once the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to make sure that they have side clearance.
12. Use a feeler gage or a dial indicator to measure the side clearance between the connecting rod caps. The rod side clearance should be 0.384-0.686 mm (0.0151-0.0270 in).