Piston & Rod Assembly
- Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston and connecting rod must be installed in cylinder block with front mark on piston facing timing belt end of engine. (Scheme 30)
- Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace piston and piston pin if any movement is felt.
- When removing piston from connecting rod, remove snap rings from piston. Heat piston to 140°F (60°C) in water. Remove piston pin using a brass drift and plastic-face hammer. Separate piston from connecting rod. Ensure piston pin diameter is within specification. See «PISTONS, PINS & RINGS»(ref-4442-S02625586632000062700000) table under ENGINE SPECIFICATIONS.
- Ensure connecting rod piston pin bushing bore diameter, crankpin bore diameter, bend and twist are within specification. See «CONNECTING RODS»(ref-4442-S16672657962000062700000) table under ENGINE SPECIFICATIONS. NOTE: Crankpin bore diameter is identified by size mark ("1", "2", "3" or "4") stamped on connecting rod. see scheme 36
- Piston pin bushing can be replaced in connecting rod if bore diameter is not within specification. Use Bushing Remover/Installer (SST 09222-30010) and press to replace bushing.
- Ensure bushing oil hole aligns with connecting rod oil hole. Hone bushing to obtain correct piston pin-to-rod clearance. See «PISTONS, PINS & RINGS»(ref-4442-S02625586632000062700000) table under ENGINE SPECIFICATIONS.
- Use caliper to measure outside diameter of connecting rod bolt, just above threads. Replace connecting rod bolt if outside diameter is less than.276" (7.01 mm).
- To reassemble, install piston on connecting rod with front mark on top of piston aligned with front mark on connecting rod. (Scheme 30) Install NEW snap ring in piston. Ensure ends of snap ring are not aligned with piston pin cutout area of piston. NOTE: With piston at 140°F (60°C), piston pin should be able to be pressed into piston using thumb pressure.
- Heat piston to 140°F (60°C) in water. Coat piston pin with engine oil. Install piston pin and remaining NEW snap ring. Ensure ends of snap ring are not aligned with piston pin cutout area of piston.
