Piston: Service and Repair
Removal Procedure^ Tools Required
- J 41507 Connecting Rod Guide.
- J 24270 Cylinder Ridge Reamer
Caution: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Remove the cylinder head.
3. Remove the oil level sensor.
4. Remove the oil pan.
5. Remove the oil pump pipe and screen.
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.
6. Mark the connecting rod cap and rod for proper reassembly.
7. Remove the connecting rod bolts.
8. Remove the connecting rod cap.
9. Install J 41507 to the connecting rod assembly. The J 41507 must be hand-tightened securely to the connecting rod.
10. Using hand pressure on J 41507, push the connecting rod assembly towards the top of the cylinder.
11. Remove the piston and connecting rod assembly.
12. Remove the J 41507.
Installation Procedure
^ Tools Required
- J 36660 Torque Angle Meter
- J 8037 Piston Ring Compressor
- J 41507 Connecting Rod Guide
Notice: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.
1. Install the piston rings to the piston. In order to provide an effective compression seal, stagger the ring gaps.
2. Turn the crankshaft to bottom dead center.
3. Lubricate the cylinder with oil.
4. Install the connecting rod bearing.
5. Install the piston and the connecting rod assembly with the ridges toward the front of the engine. Use the J 8037.
6. Raise the vehicle. Refer to Vehicle Lifting. Suitably support the vehicle.
Notice: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.
7. Use the J 41507 in order to guide the connecting rod through the cylinder.
8. Remove J 41507.
9. Install the connecting rod cap.
Notice: This bolt is designed to permanently stretch when tightened. The correct part number fastener must tie used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged. Refer to Fastener Notice in Service Precautions.
10. 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 degrees.
11. Install the oil pump pipe and screen assembly.
12. Install the oil pan.
13. Install the oil level sensor.
14. Install the cylinder head.
15. Connect the negative battery cable.