EN-45059-A Angle Meter

Equivalent regional tools:Special Tools

Piston and Connecting Rod»Remove—Piston and Connecting Rod Removal and Installation

1. The piston rings are located on the piston in the following order:
• Piston Compression Upper Ring(1)
• Piston Compression Lower Ring(2)
• Piston Oil Ring Rail(3)



2. Remove piston rings using piston ring pliers (1).




Note: The mark (3) and the arrow on the top of the piston must point in the same direction.

3. Piston Pin Retainer(1, 4)»Remove[2x]
4. Piston Pin(2)»Remove
5. Connecting Rod(5)»Remove

Warning: Refer to Safety Glasses and Compressed Air Warning

Note: The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation.

1. Clean the connecting rods (1) in solvent and dry with compressed air.
2. Inspect the connecting rod (1) for the following:
1. Signs of being twisted, bent, nicked or cracked
2. Scratches or abrasion on the connecting rod (1) bearing seating surfaces
3. If the connecting rod bores (2) contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the connecting rod (1) or connecting rod cap.
4. If the beam of the connecting rod (1) is scratched or has other damage replace the connecting rod.



5. Clean the piston with a cleaning solvent. Do NOT wire brush any parts of the piston.
6. Clean the piston ring grooves.
7. Inspect the piston on the following:
1. Cracked ring lands, skirts or pin bosses
2. Ring grooves for nicks
3. Eroded areas on the top of the piston (1)
4. Scored or damaged skirts (2)
5. Worn piston pin bores (3)
8. If there is any excessive wear, replace the piston.



9. Measure the clearance between the piston pin (1) and the piston bore. Use the following procedure:
1. Measure the piston pin outside diameter (a).
2. Measure the piston bore diameter (b).
3. Substract the piston pin outside diameter (a) from the piston bore diameter (b) to calculate the clearance.
4. For the correct value of the clearance piston pin (1) in the piston (2). Engine Mechanical Specifications



10. Inspect the connecting rod piston pin bore for any signs of pitting or erosion. If any pitting or erosion is present replace the connecting rod.
11. Measure the clearance between the piston pin (1) and the connecting rod bore. Use the following procedure:
1. Measure the piston pin outside diameter (a).
2. Measure the connecting rod bore diameter (b).
3. Substract the piston pin outside diameter (a) from the connecting rod diameter (b) to calculate the clearance.
4. For the correct value of the clearance piston pin (1) in the connecting rod (2). Engine Mechanical Specifications
12. If there is excessive clearance, replace the piston pin (1) and repeat the measurements.
13. If there is still excessive clearance, replace the connecting rod (2).
14. If there is excessive clearance, replace the piston pin (1) and repeat the measurements.
15. If there is still excessive clearance, replace the piston.



16. Install each piston ring to the cylinder (1) and measure the piston ring end gap at the points mentioned in the step below.



17. Measure piston ring end gap at point a:
1. The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
2. The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
3. The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
18. Measure piston ring end gap at point b:
1. The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
2. The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
3. The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
19. Measure piston ring end gap at point c:
1. The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
2. The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
3. The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
20. If the clearance is greater than the provided specifications, the piston rings must be replaced.



21. Measure the piston ring axial clearance (1). Compare the measurements with those provided below:
1. The piston compression upper ring clearance. For the correct value of the clearance. Engine Mechanical Specifications
2. The piston compression lower ring clearance. For the correct value of the clearance. Engine Mechanical Specifications
3. The piston oil ring rail clearance. For the correct value of the clearance.Engine Mechanical Specifications
22. If the clearance is greater than the provided specifications, replace the piston rings and repeat the measurements.
23. If the clearance is still greater than the provided specifications, replace the pistons.
24. Measure the engine cylinder bore. Engine Block Overhaul



25. Using a micrometer (2) or caliper at a right angle to the piston, measure the width of the piston (1) at 3 different measuring points from the bottom of the skirt.
1. First measure point 13 mm (0.512 in)from the bottom of the skirt.
2. Second measure point 38 mm (1.496 in)from the bottom of the skirt.
3. Third measure point 68.2 mm (2.685 in)from the bottom of the skirt.
26. Subtract the piston (1) diameter from the cylinder bore diameter in order to calculate the piston-to-bore clearance.
27. For the correct value of the clearance piston to bore. Engine Mechanical Specifications
28. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within the specification, replace the piston (1).
29. Install the connecting rod bearings and the connecting rod bearing caps.

Caution: Refer to Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution.

30. Connecting Rod Bolt»Install and tighten—Fastener Specifications



31. Using an internal measuring device, measure the connecting rod bearing diameters at 3 different measuring points (1).
32. Calculate the average connecting rod inner diameter.

    Formula: (1. result + 2. result + 3. result) / 3




33. Using a micrometer gauge, measure the connecting rod journal diameter at 2 different measuring points between (1) and (3) and between (2) and (4).
34. Calculate the average connecting rod journal diameter.

    Formula: (1. result + 2. result) / 2.

35. Subtract the average connecting rod journal diameter from the average connecting rod bearing diameter in order to determine the connecting rod bearing clearance.
36. For the correct value of the connecting rod bearing clearance. Engine Mechanical Specifications

Note: Apply engine oil to the piston pin and the connecting rod.

1. Connecting Rod(5)@Piston(3)»Install
2. Piston Pin(2)»Install
3. Piston Pin Retainer(1, 4)»Install[2x]



4. The piston rings are located on the piston in the following order:
• Piston Compression Upper Ring(1)
• Piston Compression Lower Ring(2)
• Piston Oil Ring Rail(3)



5. Install the piston rings. Use a piston ring pliers (1).



6. The piston ring gaps must be displaced 120 degrees to each other:
1. Piston compression upper ring gap (1)
2. Piston compression lower ring gap (2)
3. piston oil ring rail gap (3)

Piston and Connecting Rod»Install—Piston and Connecting Rod Removal and Installation