A. 1 5 ° K E Y S T 0 N E
C O M P R E S S IO N RING
B. RE C TA N G U LA R
C O M P R E S S IO N R ING
C. SP IR A L EXP A N D E R
RING
D. O IL C O N T R O L RING
116. RING, SNAP
117. PIN, PISTON
118. RING, ASSEMBLY
3706r4862
CLEANING AND INSPECTION
Figure 35— Piston and Components
surface is very important from the standpoint of
simulating the surface texture that would result
from a good engine break in.
• The “valleys” left by the rough hone are necessary
for proper oil retention for cylinder lubrication.
• Move the hone up and down to produce an approx
imately 45 degree crosshatch pattern. Honing trav
el technique is important for adherence to diameter,
taper and roundness specifications.
• The following is the surface roughness specifica
tion for cylinder bores.
RA (Minimum) = 0.40 Micro-meter (16 micro-inch)
RA (Maximum) = 0.90 Micro-meter (32 Micro-inch)
• Prepare the cylinder bores for use by cleaning with
a hot water and detergent wash to remove debris.
Apply clean engine oil to the bore after cleaning.
PISTO N AND CO NNECTING
ROD ASSEM BLIES
DISASSEMBLY
Disassemble (Figure 35)
XJjji Clean
• Piston.
• Remove all carbon deposits.
Important
I?
• Do not use a wire brush.
• Remove the carbon from the ring grooves. Use
a ring groove cleaning tool.
Inspect
Piston pin bore in the piston and connecting rod.
Check for scuffing, etc.
Piston for scratches, wear, etc.
Connecting rod for failure or piston pin bushing
wear. Measure the bushing for proper clearance.
Refer to “ Measuring Piston Pin to Piston Pin Bush
ing Clearance.”
Piston.
• Ring land for cracking, wear, etc.
• Ring grooves for burrs, nicks, etc.
• Skirts and pin bosses for cracking.
• Piston dome for cracking.
• Piston skirt for scuffing or deep scratches.
• Oil control ring for wear.
• Connecting rod bearing shells for scoring or
deep pitting.
PISTON MEASUREMENT
The piston skirts are barrel-shaped so the piston
diameter must be measured at a specific gage point.
m
❖
Measure
• The piston gage point diameter from the top of
the piston to 65.33 mm below to the piston skirt
(figure 36).
;
Important
• The standard production 6.5L pistons are avail
able in two grade sizes identified by a J and K
ink or metal stamped on the bottom or top of
the piston. To ensure that the piston is installed
in its original bore during reassembly, mark the
piston according to its bore. This step is neces
sary if the piston is removed from the connect
ing rod.
1. Piston rings.
2. Connecting rod bearing shells. If the shells are to
be reused, place them in a rack so they can be
installed in their original connecting rod and cap.
3. Piston pin retainer. Pry out with a small screwdriver
or scribe with a rounded end.
4. Piston pin.
• Slide the pin from the piston.
5. Piston from the connecting rod.
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
Page 919: ......