Piston: Service and Repair

PISTON/ROD ASSEMBLY FROM ENGINE
Removal






NOTE: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly.

1. Remove the connecting rod cap nuts and then remove the caps and the big end lower bearing.
2. Push each piston-connecting rod assembly toward the top of the cylinder.

Installation
Installation is the reverse of removal, noting the following:
Use a suitable ring compressor to install piston/rod assemblies.
Tighten rod bearing cap nuts to 50-53 Nm (500-530 kg. cm, 37-39 ft. lbs.)

PISTON FROM ROD
Removal






NOTE: Use the piston pin remover and installer kit tool No. 09234-33001, or equivalent, to disassemble and reassemble the piston and connecting rod.

1. Place the proper insert in the fork of the tool. Insert and position between the connecting rod and the piston.






2. Insert the proper removal tool through the hole in the arch of the tool.

NOTE: Center the piston, rod and pin assembly with the removal arbor.

3. Place assembly into a suitable press, then push the piston pin out of the connecting rod.

Installation






1. Install proper pin guide (refer to application chart) through piston and into connecting rod. Hand fit and tap pin guide into piston for proper retention.

NOTE: The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the tool.

CAUTION: If too small a pin guide used, the piston assembly will not be located centrally in the tool, and damage may occur to the fork and/or the tool.

2. Drop piston pin into the other side of the piston.
3. Install piston assembly onto fork assembly of tool, noting the following:
a. Tool will support connecting rod at the piston pin.
b. Be sure piston assembly is slid onto the fork until the pin guide contacts the fork insert.
c. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alpha-numeric setting from the application chart is obtained.
d. Turn knurled nut to lock numbered sleeve on shaft.






4. Insert the installing arbor through the hole in the arch of the tool.
5. Press piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed in.

CAUTION: Do not exceed 5C00 pounds of force when seating the pin installation arbor sleeve against the arch.






NOTE: Convex depth:
2.05-2.25 mm (0.080-0.088 in.)