38. Piston and Connecting Rod Assemble

- Tools Required
- J24086-C Piston Pin Remover/Installer

Important: Assemble the piston for the specific cylinder with the connecting rod for the corresponding crankshaft journal.
The piston and connecting rod MUST be assembled properly.





1. Insert the piston onto the press. Note the location of the alignment mark on the top of the piston.

Caution: Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.

Notice: Applying excessive heat to the connecting rod may damage or distort the rod. Rod temperature SHOULD NOT exceed 315°C (600°F). At this temperature the end of the connecting rod will turn a straw color upon visual inspection.





2. Use a torch and apply MILD heat to the pin end of the connecting rod.
Mild heating of the connecting rod will ease in piston and pin assembly.

Important: Note the alignment mark on the piston and assemble the piston and connecting rod properly.

3. Position the connecting rod so that the flat area on the bolt flange faces the front of the engine block.

Notice: After the installer hub bottoms on the support assembly, do not exceed 35000 kPa (5,000 psi) pressure, this could cause damage to the tool.





4. Use the J24086-C in order to press the piston pin into the connecting rod.





5. Measure the piston (1), pin (3), and connecting rod (2) for proper assembly.
5.1. Place the piston and connecting rod assembly onto a table or other flat surface.
Lay the flat top of the piston (1) onto the table surface.
5.2. Slide the connecting rod (2) and pin (3) to one side and hold firmly against the inside of the piston (1).
5.3. Measure the pin (3) for proper installation.
A properly installed piston pin (3) should protrude 1.27 mm (0.05 inch) from the side of the piston.

Important: When installing the piston rings onto the piston, use a ring expanding plier type tool. Do not roll the piston rings into the grooves of the piston.

Use caution and care to expand the piston rings only slightly larger than the Outside Diameter (OD) of the piston.





6. Using piston ring pliers, install the piston rings onto the piston.
6.1. Install the oil control ring spacer in the groove.
The ends of the oil control ring spacer should not overlap.
6.2. Install the lower oil control ring.
The oil control rings do not have a dimple or orientation mark and may be installed in either direction.
6.3. Install the upper oil control ring.
6.4. Stagger the three oil control ring end gaps a minimum of 90 degrees.
6.5. Using piston ring pliers, install the lower compression ring.
The lower compression ring has a dimple or orientation mark and must face the top of the piston.
6.6. Using piston ring pliers, install the upper compression ring.
The upper compression ring does not have a dimple or orientation mark and may be installed in either direction.
6.7. Stagger the compression ring end gaps a minimum of 25 mm (1.0 inch).