Tools Required
• | J 8037
Piston Ring Compressor |
Piston Selection
Important: Measurements of all components should be taken with the components at normal room temperature. For proper piston fit, the engine block cylinder bores must not have excessive wear or taper. A used piston, pin, and connecting
rod assembly may be installed, if after inspection, is within specifications.
- With a micrometer at a right angle, measure the piston outside diameter (OD). Measure the diameter 43 mm (1.69 in) from the top of the piston. Refer to
Engine Mechanical Specifications
.
- Record the piston OD.
- Adjust the micrometer to the recorded piston OD.
- Insert the
J 8087
into the micrometer and zero the gage dial.
- Using the
J 8087
, measure the cylinder bore inside diameter (ID). Measure at a point 64 mm
(2.5 in) from the top of the cylinder.
- Record the cylinder bore ID.
- Subtract the piston OD from the cylinder bore ID to determine the piston-to-bore clearance. Refer to
Engine Mechanical Specifications
.
- If the proper clearance cannot be obtained, select another piston, pin, and connecting rod assembly and again measure the clearances. If the proper fit cannot be obtained, the cylinder bore may require honing for an oversize piston.
Piston, Pin, and Connecting Rod Installation
- Lightly lubricate the following components
with clean engine oil:
• | Bearings (104) and bearing surfaces |
- Position the oil control ring end gaps a minimum of 25 mm (1.0 in) from each other.
- Position the compression ring end gaps 180 degrees opposite each other.
- Install the
J 41556
to the connecting rod.
- Install the
J 8037
onto the piston and compress the piston
rings.
Important: The piston alignment mark MUST face the front of the engine block.
- Install the piston, pin, and connecting rod assembly into the cylinder bore. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all the piston rings have entered the cylinder
bore.
- Use the
J 41556
to guide the connecting rod onto the crankshaft journal.
- Remove the
J 41556
from the connecting rod.
Notice: Refer to Fastener Notice in the Preface section.
Important: The connecting rod and cap must be assembled with the mating surfaces properly aligned.
- Install the bearing cap, bearing half, and bolts.
Tighten
- Tighten the bolts first pass to 20 N·m (15 lb ft).
- Tighten the bolts final pass to 85 degrees using the
J 45059
.
- Measure the connecting rods for the proper side clearance. Refer to
Engine Mechanical Specifications
.