64. Piston, Connecting Rod, and Bearing Installation
Piston, Connecting Rod, and Bearing InstallationTools Required
* J5239 Connecting Rod Bolt Guide Set
* J8037 Ring Compressor
* J8087 Cylinder Bore Gage
* J36660-A Torque Angle Meter
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 should not have excessive wear or taper.
A used piston and piston pin set may be reinstalled if, after cleaning and inspection, the piston and piston pin are within specifications.
1. Use the J8087 in order to measure the cylinder bore diameter. Measure at a point 64 mm (2.5 inch) from the top of the cylinder bore and 90 degrees to the crankshaft centerline.
2. Measure the J8087 with a micrometer and record the reading.
3. With a micrometer or caliper at a right angle to the piston pin bore, measure the piston 11 mm (0.433 inch) from the bottom of the skirt.
4. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
5. If the proper clearance cannot be obtained, then select another piston and measure the clearances.
If the proper fit cannot be obtained, the cylinder bore may require honing or boring.
6. When the piston-to-cylinder bore clearance is within specifications, permanently mark the top of the piston for installation into the proper cylinder.
Installation Procedure
1. Apply clean engine oil to the following components:
- The piston
- The piston rings
- The cylinder bore
- The bearing surfaces
2. Install the J5239 onto the connecting rod bolts.
3. Install the J8037 onto the piston and compress the piston rings.
Important: The mark on the top of the piston must face the front of the engine block.
When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.
4. Install the piston and connecting rod assembly, and the J8037 into the proper cylinder bore.
5. Use the J8037 and the J5239 and lightly tap the top of the piston with a wooden hammer handle.
5.1. Hold the J8037firmly against the engine block until all of the piston rings have entered the cylinder bore.
5.2. Use the J5239 in order to guide the connecting rod onto the crankshaft journal.
6. Remove the J5239.
Notice: Refer to Fastener Notice in Service Precautions.
Fastener Notice
7. Install the connecting rod caps, bearings, and nuts.
7.1. Tighten the nuts evenly on the first pass to 27 Nm (20 lb ft).
7.2. Use the J36660-A in order to tighten the nuts on the final pass an additional 70 degrees.
8. After the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to ensure that the connecting rods have side clearance.
9. Use a feeler gage or a dial indicator to measure the connecting rod side clearance between the connecting rod caps The connecting rod side clearance should be 0.15 - 0.44 mm (0.006 - 0.017 inch).