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Piston & Rod Assembly

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The powdered metal connecting rod and cap are machined for the proper clearances. The connecting rod and the cap must be used as an assembly with no repair or modifications to either mating surface. DO NOT attempt to repair the connecting rod or the cap mating surfaces. If service is required, the connecting rod and the cap must be replaced as an assembly.
NOTE: Using a paint stick or etching tool, place match marks or numbers on the connecting rods and the connecting rod caps. The connecting rods and caps MUST be assembled to their original position and direction. A stamping mark on the side of the connecting rod at the crank journal may effect component geometry. Mark the top of the piston to the specific cylinder bore.
NOTE: Mark, sort or organize the connecting rod bearings so they may be installed to their original position and location.
  1. Remove the connecting rod bolts. See Figure. Remove the connecting rod cap. Install the Connecting Rod Guide (J-41556) to the connecting rod. See Fig 1.
  2. Use a hammer and tap lightly on the end of the rod guide in order to remove the piston and connecting rod assembly from the cylinder bore.
  3. Upon removal of the piston and connecting rod assembly, assemble the connecting rod cap and bolts onto the matching connecting rod.
  4. Clean the connecting rod and the cap in solvent. Clean the connecting rod threaded bolts holes. Dry the connecting rod with compressed air.
  5. Inspect the connecting rod for twisting, nicks or gouging in the bearing bore, damage to the bearing locating slots in the bearing bore and proper fit of the connecting rod and the cap mating surfaces. Measure the connecting rod bearing bore for out-of-round. See CONNECTING RODS SPECIFICATIONS  table.
  6. Install Fork Insert (J-24086-920) into Fixture (J-24086-10). Install the piston and connecting rod assembly into the fixture. Install J-24086-107 into the piston pin and J-24086-88A through the fixture and into J-24086-107.
    7. CAUTION: After the installer hub bottoms on the support assembly, DO NOT exceed 5000 psi (35,000 kPa) of pressure, this could cause damage to tool.
  7. Press the piston pin from the piston and connecting rod assembly. The piston and pin are a matched set and are not to be serviced separately. Mark, sort or organize the piston and the matching piston pin.
    8. NOTE: Assemble the piston for the specific cylinder with the connecting rod for the corresponding crankshaft journal. The piston and connecting rod MUST be assembled properly.
  8. Install the fork insert into the fixture.
    9. CAUTION: Applying excessive heat to the connecting rod may damage or distort the rod. Rod temperature SHOULD NOT exceed 600°F (315°C). At this temperature the end of the connecting rod will turn a straw color upon visual inspection.
  9. Use a torch and apply MILD heat to the pin end of the connecting rod. Mild heating of the connecting rod will ease in piston and pin assembly.
  10. With the piston and connecting rod properly assembled, both the flat flange area of the connecting rod and the alignment mark on the top of the piston will be facing the front of the engine.
  11. Assemble the piston, connecting rod and Adapter (J-24086-16A) and install onto fixture. Adjust Installation Pin Tool (J-24086-9) to I-8. Insert Pin (J-24086-9) through fixture and to the piston pin. Press pin until the installer bottoms on fixture.
  12. Measure the piston, pin and connecting rod for proper assembly. Place the piston and connecting rod assembly onto a table or other flat surface. Lay the flat top of the piston onto the table surface.
  13. Slide the connecting rod and pin to one side and hold firmly against the inside of the piston. Measure the pin for proper installation. A properly installed piston pin should protrude 0.05" (1.27 mm) from the side of the piston. See Fig 2.
Fig 1: Using Connecting Rod Guide
G00081714Courtesy of GENERAL MOTORS CORP.
Fig 2: Installing Piston Pin
G00081715Courtesy of GENERAL MOTORS CORP.
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