Piston and Connecting Rod Disassemble and Assemble
DISASSEMBLENOTE: Mark the piston according to its cylinder position during removal. This is to ensure Installation of the piston in its original cylinder during assembly. This step is necessary when removing the pistons from the connecting rods.
1. Remove the piston rings. Discard rings if worn or damaged.
2. Remove the connecting rod bearings. If the bearings are to be reused, place them in a rack so that they may be reinstalled with the original connecting rod and cap.
3. Pry out the pin retainer with a small screwdriver or a scribe with a rounded end.
4. Remove the piston pin. The pin is a full-floating style and should slide from the piston.
5. Remove the piston from the connecting rod.
ASSEMBLE
- Tools Required
- J 39507 Piston Retaining Ring Installer, Or Equivalent
1. Install the piston to the connecting rod.
- Install the piston with the piston crown indent on the same side as the connecting rod bearing tang slots.
- When installing the piston in the cylinder, the piston crown indent on the top of the piston must be towards the outside of the cylinder.
2. Install the piston pin by applying engine oil to the pin and pushing it into place.
3. Install the retaining rings, using the piston retaining ring installer.
4. Align the open end of the retaining ring toward the bottom of the piston.
5. Use a small screwdriver and start one end of the ring in the groove.
6. Install the piston retaining ring installer through the ring and into the piston pin.
7. Press down on the ring with the pin on the tool.
8. Turn the tool-to-seat ring in the groove.
9. Inspect the retaining rings for proper assembly.
- Visually inspect the retaining ring in order to ensure that it is seated in the ring groove.
- The opening in an installed retaining ring should face downward, toward the crankshaft.
10. Measure the piston ring end gap.
11. Measure all rings in their respective cylinders.
12. Measure for ring clearance, using a feeler gauge.
13. Inspect the ring fit using the following procedure:
a. Fit each second compression ring to the piston on which it is going to be used.
b. Slip the outer surface of the second compression ring into the respective piston ring groove in order to make sure the ring does not bind. If the ring groove causes binding, dress the groove with a fine cut file. Replace distorted rings.
14. The oil ring is a two-piece ring, consisting of an expander and a scraper ring.
a. Install the oil expansion ring in the oil ring groove.
b. Install the oil ring over the oil expansion ring.
NOTE:
- When installing the compression rings, ensure that the marked side is facing the top of the piston.
- The top compression ring is a keystone style ring.
- While assembling the rings onto the piston, rotate the rings to check for binding.
- If binding occurs, inspect the ring grooves for dirt or damage, such as nicks caused by improper Installation.
15. Install the second compression ring.
16. Install the top compression ring.