Tools Required

J 24270 Ridge Reamer

1. Remove the cylinder head. Refer to Cylinder Head Replacement.
2. Remove the oil pan and the oil pump. Refer to Oil Pan Replacement (Oil Pump).
3. Remove the ridges or deposits from the upper end of the cylinder bores.
4. Turn the crankshaft until the piston is at BDC.
5. Place a cloth on top of the piston.
6. Perform the cutting procedure with a ridge reamer.
7. Turn the crankcase until the piston is at TDC.
8. Remove the cloth and the cuttings.



9. Remove the connecting rod cap.
10. Check the connecting rod and cap for identification marks.
11. Mark the parts if required. The connecting rod and cap must be kept together as mating parts.



12. Attach two short pieces 10 mm (3/8 in) hose to the connecting rod bolts. This will protect the crankshaft journal during removal.



13. Push the connecting rod and piston out of the bore.
14. Remove the connecting rod bearings. Place the bearings in a rack if they are to be reused. Using a rack will help in returning the bearings to their original locations.
15. Clean, inspect, repair or replace the components as necessary.
16. Measure the connecting rod bearing clearance, the piston clearance, the ring clearances, etc. Refer to Light Duty Truck Unit Repair Manual.

Tools Required

J 8037 Ring Compressor

Important: The cylinder walls must be clean.




1. Make sure the cylinder walls are clean.
2. Lubricate each cylinder wall lightly with engine oil.
3. Install the new pistons in the cylinders for which they were fitted.
4. Install used pistons in the cylinders from which they were removed.



5. Install the connecting rod bearings.

The bearings must be the proper size.

6. Install the bearings in the connecting rods and the connecting rod caps.
7. Lubricate the bearings with engine oil.
8. Install the piston and the connecting rod to the proper bore.
9. With the connecting rod cap removed, install two short pieces of 10 mm (3/8 in) hose onto the connecting rod studs.



10. Locate the piston ring end gaps.
11. Lubricate the piston and the rings with engine oil.
12. Without disturbing the ring end gap location, install J 8037 over the piston.
13. Install the piston so that the depression in the piston crown is toward the outside of the engine.

The connecting rod bearing tank slots must be opposite the camshaft.

14. Place the piston in its matching bore.
15. Tap the piston down into its bore using light blows with a hammer handle.
16. Guide the connecting rod to the crankshaft from beneath the vehicle with the pieces of hose.
17. Hold the ring compressor against the block until all the rings have entered the cylinder bore.



18. Remove the hoses from the connecting rod bolts.
19. Measure the connecting rod bearing clearance. Refer to the Light Duty Truck Unit Repair Manual.
20. Install the connecting rod cap and bearing.
21. Install the connecting rod cap nuts.




Tighten
Tighten the connecting rod cap nuts to 65 N·m (48 lb ft).

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.

22. Measure the connecting rod side clearance. Use a feeler gauge between the connecting rod and crankshaft. The correct clearance is between 0.17-0.63 mm (0.0067-0.0248 inch).
23. Install the oil pump (if removed). Refer to Oil Pan Replacement (Oil Pump).
24. Install the oil pan. Refer to Oil Pan Replacement (Oil Pump).
25. Install the cylinder head. Refer to Cylinder Head Replacement.