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Home >> Pontiac >> 2009 >> Vibe Base, 2.4 0, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Mechanical - 1.8L (Lay)) >> Repair Instructions - Off Vehicle >> Piston, Connecting Rod, and Bearing Cleaning and Inspection

Piston, Connecting Rod, and Bearing Cleaning and Inspection

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Illustrating Carbon Removal
    GM2017277Courtesy of GENERAL MOTORS CORP.
  1. Inspect the piston.
  2. Using a gasket scraper, remove the carbon from the top of the piston.
    3. Fig 2: Illustrating Cleaning Piston Ring Groove
    GM2017278Courtesy of GENERAL MOTORS CORP.
  3. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
    4. Fig 3: Using Solvent & Brush To Clean Piston
    GM2017279Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use a wire brush.
  4. Using a brush and solvent, thoroughly clean the piston.
  5. Using a micrometer, measure the piston diameter at right angles to the piston pin hole, and at a point 12.6 mm (0.4961 in) from the piston head.

    Specification:  Standard piston diameter: 80.461-80.471 mm (3.1677-3.1681 in)

  6. If the diameter is not as specified, replace the piston.
  7. Inspect piston oil clearance.
  8. Subtract the piston diameter measurement from the cylinder bore diameter measurement.

    Specification: 

    • Standard oil clearance: 0.029-0.052 mm (0.0011-0.0020 in)
    • Maximum oil clearance: 0.09 mm (0.0035 in)

  9. If the oil clearance is greater than the maximum, replace all the pistons. If necessary, replace the cylinder block.
    10. Fig 4: Measuring Ring-To-Piston Wall Clearance
    GM2017283Courtesy of GENERAL MOTORS CORP.
  10. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.
  11. If the groove clearance is not as specified, replace the piston.
    12. Fig 5: View Of Pushing Piston Ring Beyond Bottom Of Normal ring travel
    GM2017284Courtesy of GENERAL MOTORS CORP.
  12. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 50 mm (1.97 in) from the top of the cylinder block.
    13. Fig 6: Measuring Ring End Gap
    GM2017285Courtesy of GENERAL MOTORS CORP.
  13. Using a feeler gauge, measure the end gap.
  14. If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, replace the cylinder block.
    15. Fig 7: Measuring Piston Pin Bore Diameter
    GM2017288Courtesy of GENERAL MOTORS CORP.
  15. Using a caliper gauge, measure the piston pin bore diameter.

    Specification:  Standard piston pin bore diameter: 20.006-20.015 mm (0.7876-0.7880 in)

  16. If the diameter is not as specified, replace the piston.
    17. Fig 8: Measuring Piston Pin Diameter
    GM2017290Courtesy of GENERAL MOTORS CORP.
  17. Using a micrometer, measure the piston pin diameter.

    Specification:  Standard piston pin diameter: 20.004-20.013 mm (0.7876-0.7879 in)

  18. If the diameter is not as specified, replace the piston pin.
    19. Fig 9: Measuring Connecting Rod Pin Bore Diameter
    GM2017291Courtesy of GENERAL MOTORS CORP.
  19. Using a caliper gauge, measure the connecting rod small end bore diameter.

    Specification:  Standard connecting rod small end bore diameter: 20.012-20.021 mm (0.7879-0.7882 in)

  20. If the diameter is not as specified, replace the connecting rod.
    21. Fig 10: View Of Measuring Pin Bore Diameter Minus Pin Diameter
    GM2017293Courtesy of GENERAL MOTORS CORP.
  21. Subtract the piston pin diameter measurement from the piston pin bore diameter measurement.

    Specification: 

    • Standard oil clearance: -0.001 to +0.005 mm (-0.00004 to +0.0002 in)
    • Maximum oil clearance: 0.010 mm (0.0004 in)

  22. If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set.
  23. Subtract the piston pin diameter measurement from the connecting rod small end bore diameter measurement.

    Specification: 

    • Standard oil clearance: 0.00-0.011 mm (0.0002-0.0004 in)
    • Maximum oil clearance: 0.014 mm (0.0006 in)

  24. If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set.
    25. Fig 11: Checking Connecting Rod Alignment
    GM2017296Courtesy of GENERAL MOTORS CORP.
  25. Using a connecting rod aligner and feeler gauge, check the connecting rod alignment.
  26. Check for misalignment.

    Specification:  Maximum misalignment: 0.05 mm (0.0020 in) per 100 mm (3.94 in)

  27. If the misalignment is greater than the maximum, replace the connecting rod.
    28. Fig 12: Checking Connecting Rod Twist
    GM2017297Courtesy of GENERAL MOTORS CORP.
  28. Check for twist.

    Specification:  Maximum twist: 0.15 mm (0.0059 in) per 100 mm (3.94 in)

  29. If the twist is greater than the maximum, replace the connecting rod.
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