GM 96068583 Piston,Engine

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Prior to removing the piston/connecting rod assemblies, remove the cylinder head, the oil pan and the oil pickup. Use your fingernail to feel if a ridge has formed at the upper limit of ring travel (about 1/4-inch down from the top of each cylinder). If carbon deposits or cylinder wear have produced ridges, they must be completely removed with a special ridge reamer tool. Follow the manufacturer's instructions provided with the tool. Failure to remove the ridges before attempting to remove the piston/connecting rod assemblies may result in piston breakage. After the cylinder ridges have been removed, turn the engine upside-down so the crankshaft is facing up. Before the connecting rods are removed, check the end play with feeler gauges. Slide them between the first connecting rod and the crankshaft throw until the play is removed. The end play is equal to the thickness of the feeler gauge(s). If the end play exceeds the service limit, new connecting rods will be required. If new rods (or a new crankshaft) are installed, the end play may fall under the specified minimum. Repeat the procedure for the remaining connecting rods. Check the connecting rods and caps for identification marks. If they aren't plainly marked, use a small center punch to make the appropriate number of indentations on each rod and cap (1, 2, 3 or 4, depending on the cylinder with which they're associated). Loosen each of the connecting rod cap nuts 1/2-turn at a time until they can be removed by hand. Remove the number one connecting rod cap and bearing insert. Don't drop the bearing insert out of the cap. Slip a short length of plastic or rubber hose over each connecting rod cap bolt to protect the crankshaft journal and cylinder wall as the piston is removed. Remove the bearing insert and push the connecting rod/piston assembly out through the top of the engine. Use a wooden hammer handle to push on the upper bearing surface in the connecting rod. If resistance is felt, double-check to make sure that the entire ridge was removed from the cylinder. Repeat the procedure for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective connecting rods and install the cap nuts finger tight. Leaving the old bearing inserts in place until reassembly will help prevent the connecting rod bearing surfaces from being accidentally nicked or gouged. Don't separate the pistons from the connecting rods.

The original piston rings should be cautiously removed from the pistons using a piston ring installation tool. Care should be taken not to damage the pistons during this process.

After the piston/connecting rod assembly is installed in the cylinder, the connecting rod bearing oil clearance should be checked using Plastigage.