Piston: Service and Repair
REMOVAL PROCEDURE^ Tools Required
- J 24270 Cylinder Bore Ridge Reamer
- J 41507 Connecting Rod Assembly Guide
Notice: Refer to Engine Emission Notice in Service Precautions.
1. Remove the cylinder head.
2. Clean the carbon from the top end of the cylinder.
Notice: If there is a pronounced ridge at the top of the piston travel, the ridge must be removed with a ridge reamer before the piston and connecting rod assembly are removed. Applying force may break the piston rings or damage the piston.
3. Use the following procedure in order to remove the ring ridge, as necessary:
3.1. Turn the crankshaft until the piston is at Bottom Dead Center (BDC).
3.2. Place a cloth on top of the piston.
3.3. Use the J 24270 in order to remove the piston ring ridge.
3.4. Remove the J24270.
3.5. Turn the crankshaft so that the piston is at Top Dead Center (TDC).
3.6. Remove the cloth and cutting debris.
4. Remove the oil pan.
5. Turn the crankshaft to Bottom Dead Center (BDC).
6. Mark the piston with the number of the cylinder from which it is being removed.
7. Mark the connecting rod and the rod cap so that they can be assembled correctly.
8. Remove the connecting rod bolts.
9. Remove the connecting rod cap and lower connecting rod bearing.
10. Install the J 41507 on the connecting rod.
Caution: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.
Important: Do not use force when removing the connecting rod and piston. Avoid breaking the piston rings and damaging the piston.
11. Remove the piston, connecting rod and upper connecting rod bearing. Push out the piston, connecting rod and upper connecting rod bearing with the J 41507.
12. Inspect the piston, connecting rod and connecting rod bearing.
INSTALLATION PROCEDURE
^ Tools Required
- J 8037 Ring Compressor
- J 36660 Electronic Torque Angle Meter
- J 41507 Connecting Rod Assembly Guide
Notice: Refer to Engine Emission Notice in Service Precautions.
1. Install the piston rings to the piston. Stagger the ring gaps to provide an effective compression seal.
2. Turn the crankshaft to Bottom Dead Center (BDC).
3. Lubricate the cylinder with oil.
4. Install the upper connecting rod bearing.
5. Install the J 41507 on the connecting rod.
6. Align the piston and the connecting rod with the arrow (1) toward the front of the engine.
Notice: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.
7. Install the piston and connecting rod using the J 8037.
8. Install the piston into the bore by lightly tapping the top of the piston with a wooden hammer handle.
Notice: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will etch the bearing surface.
Important: Make sure that the bearing cap bolt holes and the cap mating surfaces are clean and dry. The inserts will project slightly when put into place. Make sure the inserts project an equal distance on both sides. Make sure that the insert tangs are engaged.
9. Install the bearing inserts to a clean and dry connecting rod and cap.
10. Measure the rod bearing clearance. If the readings are within limits, select a suitable set of inserts. If the readings are unsatisfactory and available inserts will not correct the clearance, replace the crankshaft.
11. Lubricate the bearing surfaces and the crankshaft journal surfaces with clean engine oil.
12. Remove the J 41507.
Important: Carefully tap the bearing cap into place. Do not pull the cap down with the cap bolts.
13. Install the connecting rod cap and lower connecting rod bearing.
Notice: Refer to Fastener Notice in Service Precautions.
14. Install the connecting rod cap bolts.
^ Tighten the connecting rod bolts to 27 Nm (20 ft. lbs.). Use the J 36660 in order to rotate the bolts an additional 50°.
15. Pry the connecting rod back and forth with a suitable tool and check for binding. If necessary, loosen and retighten the bearing cap.
16. Measure the connecting rod side clearance.
17. Install the cylinder head.
18. Install the oil pan.