Piston: Service and Repair
Removal Procedure^ Tools Required
- J 5239 Connecting Rod Bolt Guide Set
- J 24270 Cylinder Bore Ridge Reamer
1. Remove the cylinder head(s). Refer to Cylinder Head Replacement (Left Front) and/or Cylinder Head Replacement (Right Rear).
2. Use the following procedure in order to remove the ring ridge, as necessary:
2.1. Turn the crankshaft until the piston is at the bottom of its stroke.
2.2. Place a cloth on top of the piston.
2.3. Use the J 24270 in order to remove the piston ring ridge.
2.4. Turn the crankshaft so that the piston is at the top of its stroke.
2.5. Remove the cloth and cutting debris.
3. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
4. Remove the oil pan. Refer to Oil Pan Replacement.
5. Remove the oil pump. Refer to Oil Pump Replacement.
6. Remove the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement.
7. Turn the crankshaft until the piston and rod assembly to be serviced is at Bottom Dead Center (BDC).
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.
8. Remove the connecting rod nuts.
9. Remove the connecting rod cap.
10. Remove the lower connecting rod bearing.
Notice: Install thread protector in order to avoid damage to the crankshaft journal.
11. Install the J 5239.
12. Push the piston and rod up through the cylinder.
13. Lower the vehicle.
14. Remove the connecting rod, upper connecting rod bearing and piston out of the top of the engine block.
15. Wipe oil from the connecting rod bearings and crankshaft connecting rod journal.
16. Inspect the connecting rod bearings. Refer to Piston, Connecting Rod and Bearings Clean/Inspect.
17. Inspect the connecting rod cap and connecting rod. Refer to Piston, Connecting Rod and Bearings Clean/Inspect.
18. Inspect the crankshaft connecting rod journal. Refer to Crankshaft and Bearings Clean and Inspect.
19. Clean the cylinder bores with a light honing.
20. Clean the cylinder bores with hot water and detergent.
21. Swab the bores with a clean, dry cloth.
22. Swab the bores with new engine oil and a clean, dry cloth.
Installation Procedure
^ Tools Required
- J 5239 Connecting Rod Bolt Guide Set
- J 8037 Piston Ring Compressor
- J 36660 Electronic Torque Angle Meter
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 Vehicle Lifting.
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: Refer to Fastener Notice in Service Precautions.
15. Install the connecting rod cap nuts.
Tighten the connecting rod nuts to 20 Nm (15 ft. lbs.). Use the J 36660 in order to rotate the nuts an additional 75 degrees.
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 Specifications for the connecting rod side clearance.
18. Install the crankshaft oil deflector. Refer to Crankshaft Oil Deflector Replacement.
19. Install the oil pump. Refer to Oil Pump Replacement.
20. Install the oil pan. Refer to Oil Pan Replacement.
21. Lower the vehicle.
22. Install the cylinder head(s). Refer to Cylinder Head Replacement (Right Rear) and/or Cylinder Head Replacement (Left Front).