Piston: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
3. Drain the cooling system. Recover the coolant. Refer to Cooling System Service and Repair.
4. Remove the cylinder heads.
5. Remove the oil pan.
6. Mark the piston with the number of the cylinder from which the piston is being removed.
7. Mark the connecting rod and the rod cap so that you can correctly assemble the parts.
8. Turn the crankshaft to bottom dead center.
9. Clean the carbon from the top end of the cylinder.
10. Remove the connecting rod cap.





11. Remove the piston and the rod assembly using a suitable tool.

Installation Procedure

^ Tools Required
- J 8037 Universal Piston Ring Compressor





1. Lubricate the cylinder wall and the piston rings. Use clean engine oil.
2. Turn the crankshaft to bottom dead center.
3. Install the connecting rod stud thread protector.

Notice: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.





4. Install the J 5239.

Important: Ensure that the arrow on the top of the piston faces towards the front of the engine.





5. Install the piston and the connecting rod assembly.
6. Remove the thread protectors.
7. Install the connecting rod bearing.

Important: Carefully tap the bearing cap into place using a suitable tool. Do not pull the cap down with the cap bolts or the nuts.

8. Seat the bearing caps.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the rod bearing cap nuts.
^ Tighten the rod cap nuts to 20 Nm (15 ft. lbs.). Use the J 36660 in order to tighten the nuts an additional 75 degrees.

10. Inspect the connecting rod for binding. Pry the rod back and forth using a suitable tool. Loosen the bearing cap if the rod binds. Retighten the bearing cap.
11. Install the oil pan.
12. Install the cylinder head.
13. Fill the cooling system. Refer to Cooling System Service and Repair.
14. Connect the negative battery cable.