Piston: Service and Repair

Disassembly

1. NOTE: Mark the pistons to ensure assembly with same connecting rod and installation in the same cylinders from which they were removed.

Remove pistons and connecting rods as outlined.

2. Remove piston rings from pistons as outlined.







3. WARNING: COVER THE END OF THE PIN BORE WITH A HAND OR SHOP RAG WHEN REMOVING THE RETAINER RING SINCE IT HAS A TENDENCY TO SPRING OUT. EYE PROTECTION SHOULD BE WORN.


Using 0-ring Tool T7IP-19703-C, remove the two piston pin retainer rings.







4. Gradually heat pistons to approximately 70-130°C (160-275°F).







5. Using Piston Pin Tool D8IL-6135-A or equivalent, push piston pin from piston and connecting rod.

Assembly


1. Clean and inspect pistons.


2. Clean and inspect connecting rod.


3. Verify that all parts to be assembled are for same cylinder.


4. NOTE: When installing piston pin, check each end of piston pin for identification mark. If identification mark is present, install piston pin with identification mark toward front of engine.

NOTE: Connecting rods may be installed into pistons with connecting rod identification mark in either direction.


Install new piston pin retainer ring into one side of piston pin bore.







5. Gradually heat pistons to approximately 70-135°C (160-275°F).

6. Start piston pin in piston and connecting rod. This may require a very light tap with a mallet.







7. Using Piston Pin Remover and Replacer D81L-6135-A or equivalent, push piston pin through piston until piston pin bottoms on piston retainer ring.

8. Install a new piston pin retainer ring on other side of the piston bore.


9. After assembly, make sure connecting rod swings smoothly.

10. Install piston rings as outlined. Service and Repair


11. Install pistons and connecting rods as outlined. Service and Repair