Piston & Rod Assembly
TOOL REQUIRED^ J 8037 Piston Ring Compressor
^ J 24270 Ridge Reamer
REMOVAL
1. Remove the engine.
2. Remove the cylinder head.
3. Remove the crankshaft oil deflector.
4. Mark the piston with the number of the cylinder from which it is being removed.
5. Mark the connecting rod and the rod cap. Each rod cap must be reassembled with the connecting rod from which it was removed.
6. Turn the crankshaft to bottom dead center (BDC).
7. Clean the carbon from the top end of the cylinder.
CAUTION: 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.
8. If there is a pronounced ridge in the cylinder at the top of the piston travel, remove it by performing the following procedure:
a. Rotate the crankshaft until the piston is at BDC.
b. Place a cloth on top of the piston.
c. Perform the cutting operation using the Ridge Reamer.
d. Remove the cloth and the cuttings.
9. Remove the connecting rod cap.
10. Install the thread protector in order to avoid damage to the crankshaft journal.
WARNING: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.
11. Push out the piston and connecting rod with a suitable tool. Do not use force. Avoid breaking the piston rings. Do not damage the piston.
INSTALLATION
1. Lubricate the cylinder wail and the piston rings with clean engine oil.
2. Turn the crankcase to BDC.
3. Install the connecting rod thread protector.
4. In order to provide an effective compression seal, stagger the ring gaps.
5. Install the Piston Ring Compressor.
6. Align the piston and the connecting rod with the arrow on the piston top toward the front of the engine.
7. Be sure the arrow on the top of the piston faces towards the front of the engine.
8. Install the piston with the "L" stamp in the left bank only. Install the piston with the "R" stamp in the right bank only.
CAUTION: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.
9. Remove the thread protectors.
CAUTION: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.
NOTE: Make sure the bearing cap bolt holes and the cap mating surfaces are clean and dry.
10. Install the bearing inserts onto the clean and dry connecting rod and cap.
CAUTION: Upper and lower inserts may be different. Do not obstruct any oil passages. The inserts will project slightly when put into place. Make sure the inserts project an equal distance on both sides. Make sure the insert tangs are engaged.
11. Measure the bearing clearance.
12. 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.
13. Lubricate the bearing surfaces and the crankshaft journal surfaces with Engine Oil Supplement (EOS) GM P/N 1052367 or equivalent.
CAUTION: Carefully tap the bearing cap into place. Do not pull the cap into place with the cap bolts or nuts.
14. Install the, bearing cap. Tighten the bearing cap nuts to 20 Nm (15 ft. lbs.) + 75 degrees.
15. Pry the connecting rod back and forthwith a suitable tool. Check for binding. If Necessary, loosen and retighten the bearing cap.
16. Measure the connecting side clearance.
17. Install the crankshaft oil deflector.
18. Install the cylinder head.
19. Install the engine.