For 1990-2009 cars

#### Tools Required

J 8087 Cylinder Bore Gage

Caution: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.

Important: Measurement of all components should be taken with the components at room temperature. Do not use a wire brush in order to clean any part of the piston.

1. Clean the piston and connecting rod in solvent.
2. Clean the piston ring grooves with a suitable ring groove cleaning tool.
3. Clean the piston oil lubrication holes and slots.
4. Inspect the piston for the following:

• | Eroded areas (1) on the top of the piston

• | Scuffed or damaged skirt (2)

• | Damage to the pin bore (3)

• | Cracks in the piston ring lands, the piston skirt, or the pin bosses

• | Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind

5. Inspect the piston pin for scoring, wear or other damage.
6. Measure the piston ring-to-piston ring groove side clearance.

6.1. | Insert the edge of the piston ring into the piston ring groove.

6.2. | Roll the piston ring completely around the piston ring groove.

• | If binding is caused by distorted piston ring groove, replace the piston.

• | If binding is caused by a distorted piston ring, replace the piston ring.

7. Measure the piston ring side clearance with a feeler gage.
8. If the side clearance is too small try another ring set.
9. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly.

• | Proper ring-to-piston ring groove clearance for the top ring is 0.04-0.086 mm (0.00158-0.00338 in).

• | Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.087 mm (0.00158-0.00342 in).

10. Measure the piston pin diameter using an outside micrometer.

Important: When fitting pistons, consider both the pistons and the cylinder bore conditions together. Production and service pistons have the same nominal weight and may be intermixed without affecting engine balance. If necessary, used pistons may be fitted selectively to any cylinder of the engine, providing the pistons are in good condition and the same weight. Do not cut oversize pistons down or the engine balance may be affected. Finish hone when selecting the piston.

11. Measure the piston pin bore using an inside micrometer.
12. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
13. Piston-to-piston pin bore clearance must measure 0.0096-0.0215 mm (0.0004-0.0008 in). Replace the piston and the piston pin if the piston and the piston pin are not within specifications.
14. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin removed, and record the measurement. Measure the piston at 49.8 mm (1.9606 in) from dome of piston. Piston diameter must measure 88.966-88.984 mm (3.5026-3.5033 in). Replace the piston and the pin as an assembly if the piston is not within specifications.
15. Measure the cylinder bore, using J 8087 .
16. Measure the J 8087 . Record this reading.
17. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore clearance. The cylinder bore clearance must be 0.07-0.053 mm (0.0013-0.0027 in).
18. If a used piston is not acceptable, inspect the service piston sizes and determine if a new piston may be selected. Service pistons are available in standard, and 0.5 mm (0.012 in) oversize.
19. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
20. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds 0.005 mm (0.0002 in) the connecting rod must be replaced.
21. Inspect the connecting rod for twisting.

21.1. | Install the connecting rod cap.

21.2. | Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting.

21.3. | Do not attempt to straighten the connecting rod.

Ensure that the connecting rod meets the following conditions:

• | The connecting rods are not bent more than 0.18 mm (0.007 in).

• | The connecting rods are not twisted more than 0.038 mm (0.0015 in).

21.4. | Replace any bent or twisted connecting rods.

21.5. | Inspect the new connecting rods before using the new rods.

22. Inspect the connecting rod for damage to the bearing cap and bolt threads.
23. Measure the piston compression ring end gap.

| Important: Fit each compression ring to the cylinder in which it will be used.

23.1. | Place the compression ring into the cylinder bore.

23.2. | Push the compression ring into the bottom of the cylinder bore to approximately 6.5 mm (0.25 in) above ring travel.

The ring must be square to the cylinder wall.

23.3. | Use a feeler gage in order to measure the end gap. The first compression ring end gap must measure 0.15-0.36 mm (0.006-0.014 in), the second compression ring, 0.5-0.71 mm (0.019-0.027 lb in).

23.4. | Select another size ring set if the end gap exceeds specification. If ring gap clearance is below specification, increase the gap by carefully filling off excess material.

24. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatigue.
25. Inspect the connecting rod bearings for excess scoring or discoloration.
26. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
27. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
28. Inspect the inside of the connecting rod bearing and the outside diameter fo the connecting rod bearing journal for wear. This indicates high spots.