Piston

DESCRIPTION The pistons (Figure 1)(2) are made of a high strength aluminum alloy. The connecting rods (1) are made of forged powdered metal, with a "fractured cap" design. A full floating piston pin is used to attach the piston to the connecting rod.

1 - CONNECTING ROD 2 - PISTON 3 - PISTON PIN 4 - OIL SLINGER SLOT

CAUTION: Do not use a metal stamp to mark connecting rods as damage may result,

instead use ink or a scratch awl.

The pistons (2) are made of a high strength aluminum alloy. The connecting rods (1) are made of forged powdered metal, with a "fractured cap" design. A full floating piston pin is used to attach the piston to the connecting rod. See Fig. 112.

1 - FRONT 2 - BORE GAUGE 3 - CYLINDER BORE 4 - 38 MM (1.5 in)

1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. See Fig. 118.

2. Measure the inside diameter of the cylinder bore (3) at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B.

1 - MOLY COATED 2 - MOLY COATED

3. The coated pistons (1,2) will be serviced with the piston pin and connecting rod pre-assembled. See Fig. 119. 4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston (1,2) will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY . To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required. 5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.

1. Disconnect negative cable from battery. 2. Remove the following components: Oil pan and gasket/windage tray. See REMOVAL. Cylinder head covers. See REMOVAL. Timing chain cover. See REMOVAL. Cylinder head(s). See REMOVAL. 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.

CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur

NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool.

CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.

5. Remove connecting rod cap. Install the Connecting Rod Guides 8507 into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.

CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur

6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.

CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged.

1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves.

CAUTION: DO NOT remove the piston pin from the piston and connecting rod

Check the connecting rod journal for excessive wear, taper and scoring.

Check the connecting rod for signs of twist or bending.

Check the piston for taper and elliptical shape before it is fitted into the cylinder bore.

Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.

1 - "F" TOWARD FRONT OF ENGINE 2 - OIL SLINGER SLOT 3 - RING COMPRESSOR 4 - SPECIAL TOOL 8507

1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Ensure that tabs in bearing shell aligns with slots in connecting rod. Verify that parting line of bearing is aligned with parting line of connecting rod. 4. Lubricate bearing surface with clean engine oil. 5. Install Connecting Rod Guides 8507 (4) onto connecting rod bolt threads. See Fig. 120.

1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SLINGER SLOT

6. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot (2) faces the front of the engine. See Fig. 121. 7. Wipe cylinder bore clean and lubricate with engine oil. 8. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 9. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal.

CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.

10. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 N.m (20 ft. lbs.) plus 90°. 11. Install the following components: Cylinder head(s). See INSTALLATION. Timing chain and cover. See INSTALLATION. Cylinder head covers. See INSTALLATION. Oil pan and gasket/windage tray. See INSTALLATION. 12. Fill crankcase with proper engine oil to correct level. 13. Connect negative cable to battery.

RINGS-PISTON