Connecting Rod Measurement
- Clean the connecting rods
in solvent and dry with compressed air.
- Inspect the connecting rods for the following:
• | Signs of being twisted, bent, nicked, or cracked |
• | Scratches or abrasion on the rod bearing seating surface |
- If the connecting rod bores contain minor scratches or abrasions,
clean the bores in a circular direction with a light emery paper. DO NOT scrape
the rod or rod cap.
- If the beam of the rod is scratched or has other damage replace
the connecting rod.
- Measure the piston pin to connecting rod bore using the following
procedure:
5.1. | Using an outside micrometer, take two measurements of the piston
pin in the area of the connecting rod contact. |
5.2. | Using an inside micrometer, measure the connecting rod piston
pin bore. |
5.3. | Subtract the piston pin diameter from the piston pin bore diameter. |
5.4. | The clearance should not be more than 0.021 mm (0.0008 in). |
- If there is excessive clearance, replace the piston pin.
- If there is still excessive clearance, replace the connecting
rod.
Piston Measurement
- Clean the piston skirts
and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
- Clean the piston ring grooves with a groove cleaner. Make sure
oil ring holes and slots are clean.
- Inspect the pistons for the following conditions:
• | Cracked ring lands, skirts, or pin bosses |
• | Ring grooves for nicks, burrs that may cause binding |
• | Warped or worn ring lands |
• | Eroded areas at the top of the piston (1) |
• | Scuffed or damaged skirts (2) |
• | Worn piston pin bores (3) |
- Replace pistons that show any signs or damage or excessive wear.
- Measure the piston pin bore to piston pin clearances using the
following procedure:
5.1. | Piston pin bores and pins must be free of varnish or scuffing. |
5.2. | Use an outside micrometer to measure the piston pin in the piston
contact areas. |
5.3. | Using an inside micrometer, measure the piston pin bore. |
5.4. | Subtract the measurement of the piston pin bore from the piston
pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). |
5.5. | If the clearance is excessive, determine which component is out
of specification. |
- Measure the piston ring
end gap using the following procedure:
6.1. | Place the piston ring in the area of the bore where the piston
ring will travel (approximately 25 mm or 1 inch down from the
deck surface). Be sure the ring is square with the cylinder bore by positioning
the ring with the piston head. |
6.2. | Measure the end gap of the piston ring with feeler gages. Compare
the measurements with those provided below: |
• | The top compression ring end gap should be 0.20-0.40 mm
(0.0060-0.015 in). |
• | The second compression ring end gap should be 0.35-0.55 mm
(0.0137-0.0216 in). |
• | The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). |
6.3. | If the clearance exceeds the provided specifications, the piston
rings must be replaced. |
6.4. | Repeat the procedure for all the piston rings. |
- Measure the piston ring
side clearance using the following procedure:
7.1. | Roll the piston ring entirely around the piston ring groove. If
any binding is caused by a distorted piston ring, replace the ring. |
7.2. | With the piston ring on the piston, use feeler gages to check
clearance at multiple locations. |
7.3. | The clearance between the surface of the top piston ring and the
ring land should be no greater than 0.075 mm (0.0030 in). |
7.4. | If the clearance is greater than specifications, replace the piston
ring. |
7.5. | If the new ring does not reduce the top ring side clearance to
0.075 mm (0.0030 in) or less, install a new piston. |
- The top compression ring may be installed with either side up.
There is a locating dimple on the 2nd compression ring near the end for identification
of the top side. Install the 2nd compression ring with the dimple facing
up.
- The clearance between the surface of the second piston ring and
the ring land should be no greater than 0.069 mm (0.0026 in).
- If the new ring does not reduce the clearance to 0.069 mm
(0.0026 in) or less, install a new piston.
- Measure piston width using
the following procedure:
11.1. | Using an outside micrometer, measure the width of the piston 14.5 mm
(0.570 in) above the bottom of the piston skirt at the thrust surface
perpendicular to the centerline of the piston pin. |
11.2. | Compare the measurement of the piston to its original cylinder
by subtracting the piston width from the cylinder diameter. |
11.3. | The proper clearance specification for the piston is 0.010-0.041 mm
(0.0006-0.0016 in). |
- If the clearance obtained through measurement is greater than
these specifications and the cylinder bores are within specification, replace
the piston.
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 and pin set may be reinstalled if, after cleaning and
inspection, they are within specifications.
- Inspect the engine block cylinder bore. Refer to
Engine Block Cleaning and Inspection
.
- Inspect the piston and the piston pin. Refer to
Piston, Connecting Rod, and Bearing Cleaning and Inspection
.
- Use a bore gauge and measure the cylinder bore diameter. Measure
at a point 64 mm (2.5 in) from the top of the cylinder bore.
- Measure the bore gauge
with a micrometer and record the reading.
- With a micrometer or caliper
at a right angle to the piston, measure the piston 14 mm (0.570 in)
from the bottom of the skirt.
- Subtract the piston diameter from the cylinder bore diameter in
order to determine piston-to-bore clearance.
- For proper piston-to-bore clearance. Refer to
Engine Mechanical Specifications
.
- If the proper clearance cannot be obtained, select another piston
and measure for the clearances.
- If the proper fit cannot be obtained, hone the cylinder bore or
replace the cylinder block.
- When the piston-to-cylinder bore clearance is within specifications,
mark the top of the piston using a permanent marker for installation to the
proper cylinder. Refer to
Separating Parts
.
Connecting Rod Measurement
- Clean the connecting rods in solvent
and dry with compressed air.
- Inspect the connecting rods for the following:
• | Signs of being twisted, bent, nicked, or cracked |
• | Scratches or abrasion on the rod bearing seating surface |
- If the connecting rod bores contain minor scratches or abrasions,
clean the bores in a circular direction with a light emery paper. DO NOT
scrape the rod or rod cap.
- If the beam of the rod is scratched or has other damage replace
the connecting rod.
- Measure the piston pin to connecting rod bore using the following
procedure:
5.1. | Using an outside micrometer, take two measurements of the piston
pin in the area of the connecting rod contact. |
5.2. | Using an inside micrometer, measure the connecting rod piston
pin bore. |
5.3. | Subtract the piston pin diameter from the piston pin bore diameter. |
5.4. | The clearance should not be more than 0.021 mm (0.0008 in). |
- If there is excessive clearance, replace the piston pin.
- If there is still excessive clearance, replace the connecting
rod.
Piston Measurement
- Clean the piston skirts and the pins
with a cleaning solvent. DO NOT wire brush any part of the piston.
- Clean the piston ring grooves with a groove cleaner. Make sure
oil ring holes and slots are clean.
- Inspect the pistons for the following conditions:
• | Cracked ring lands, skirts, or pin bosses |
• | Ring grooves for nicks, burrs that may cause binding |
• | Warped or worn ring lands |
• | Eroded areas at the top of the piston (1) |
• | Scuffed or damaged skirts (2) |
• | Worn piston pin bores (3) |
- Replace pistons that show any signs or damage or excessive wear.
- Measure the piston pin bore to piston pin clearances using the
following procedure:
5.1. | Piston pin bores and pins must be free of varnish or scuffing. |
5.2. | Use an outside micrometer to measure the piston pin in the piston
contact areas. |
5.3. | Using an inside micrometer, measure the piston pin bore. |
5.4. | Subtract the measurement of the piston pin bore from the piston
pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). |
5.5. | If the clearance is excessive, determine which component is out
of specification. |
- Measure the piston ring end gap using
the following procedure:
6.1. | Place the piston ring in the area of the bore where the piston
ring will travel (approximately 25 mm or 1 inch down from the
deck surface). Be sure the ring is square with the cylinder bore by positioning
the ring with the piston head. |
6.2. | Measure the end gap of the piston ring with feeler gages. Compare
the measurements with those provided below: |
• | The top compression ring end gap should be 0.20-0.40 mm
(0.0060-0.015 in). |
• | The second compression ring end gap should be 0.35-0.55 mm
(0.0137-0.0216 in). |
• | The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). |
6.3. | If the clearance exceeds the provided specifications, the piston
rings must be replaced. |
6.4. | Repeat the procedure for all the piston rings. |
- Measure the piston ring side clearance
using the following procedure:
7.1. | Roll the piston ring entirely around the piston ring groove. If
any binding is caused by a distorted piston ring, replace the ring. |
7.2. | With the piston ring on the piston, use feeler gages to check
clearance at multiple locations. |
7.3. | The clearance between the surface of the top piston ring and the
ring land should be no greater than 0.075 mm (0.0030 in). |
7.4. | If the clearance is greater than specifications, replace the piston
ring. |
7.5. | If the new ring does not reduce the top ring side clearance to
0.075 mm (0.0030 in) or less, install a new piston. |
- The top compression ring may be installed with either side up.
There is a locating dimple on the 2nd compression ring near the end for identification
of the top side. Install the 2nd compression ring with the dimple facing
up.
- The clearance between the surface of the second piston ring and
the ring land should be no greater than 0.069 mm (0.0026 in).
- If the new ring does not reduce the clearance to 0.069 mm
(0.0026 in) or less, install a new piston.
- Measure piston width using the following
procedure:
11.1. | Using an outside micrometer, measure the width of the piston 14.5 mm
(0.570 in) above the bottom of the piston skirt at the thrust surface
perpendicular to the centerline of the piston pin. |
11.2. | Compare the measurement of the piston to its original cylinder
by subtracting the piston width from the cylinder diameter. |
11.3. | The proper clearance specification for the piston is 0.010-0.041 mm
(0.0006-0.0016 in). |
- If the clearance obtained through measurement is greater than
these specifications and the cylinder bores are within specification, replace
the piston.
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 and pin set may be reinstalled if, after cleaning and
inspection, they are within specifications.
- Inspect the engine block cylinder bore. Refer to
Engine Block Cleaning and Inspection
.
- Inspect the piston and the piston pin. Refer to
Piston, Connecting Rod, and Bearing Cleaning and Inspection
.
- Use a bore gauge and measure the cylinder bore diameter. Measure
at a point 64 mm (2.5 in) from the top of the cylinder bore.
- Measure the bore gauge with a micrometer
and record the reading.
- With a micrometer or caliper at a right
angle to the piston, measure the piston 14 mm (0.570 in) from
the bottom of the skirt.
- Subtract the piston diameter from the cylinder bore diameter in
order to determine piston-to-bore clearance.
- For proper piston-to-bore clearance. Refer to
Engine Mechanical Specifications
.
- If the proper clearance cannot be obtained, select another piston
and measure for the clearances.
- If the proper fit cannot be obtained, hone the cylinder bore or
replace the cylinder block.
- When the piston-to-cylinder bore clearance is within
specifications, mark the top of the piston using a permanent marker for
installation to the proper cylinder. Refer to
Separating Parts
.