Piston replacement, connector rod, and support

Steps

To make the replacement of the piston for the Aveo model, it's necessary to have the following tools:

  • KM-470-B Angular torque gauge.
  • J 24086-B (KM-427) Piston pin extractor / installer.
  • Measurement of angle J 45059.
  • Steps 1 - DISASSEMBLY PROCEDURE



    To start the disassembly, the following components must be removed:

  • The cylinder head together with the intake manifold and the connected exhaust manifold.
  • The crankcase of the engine.
  • The recovery tube bolts/oil pump.
  • The recovery tube/oil pump.


  • Once you have performed the procedures described above, you must move the piston to the bottom of the piston movement. Then, you must make a mark on the cap of the connecting rod. Next, it will be necessary to remove the bolts from the connecting rod cap, then the connecting rod cap and the lower connecting rod bearing, and finally the upper piston rod bearing.


    Now you must make a push on the cylinder wall.



    Warning:

    - Handle the piston with care. The worn piston rings are very sharp and can cause personal injury.




    This will achieve the release of the piston and proceed to remove it, but be careful, it is advisable to use a piston ring expander tool to extend the piston rings and thus avoid injury.


    Now remove the piston rings.



    Remove the piston pin from the connecting rod and piston assembly with tool J 24086-B and proceed to separate the piston from the connecting rod.

    Steps 2 - INSTALLATION

    Warning:

    - Avoid contact with moving parts and hot surfaces while working near a running engine to prevent physical injury.


    The installation will be a little easier. The first thing to do is to align the notch in the piston and the connecting rod so that the correct sides are facing the front of the engine.


    Then, you must install the piston pin guide through the piston and the connecting rod.


    Cover the piston pin with clean oil, and install the piston pin on the opposite side of the piston, and the piston pin on the connecting rod and piston assembly with tool J 24086-B.




    Once this is done, you must select a set of new piston rings. Before making such selection, observe the space of the piston ring with a lamella gauge. You'll have to increase this space by carefully filing excess material if the piston ring gap is below specifications.




    Measure the side space of the piston ring again using a lamella gauge. If the piston ring is too thick, try another piston ring.


    If you can not find a piston ring that conforms to the specifications, the piston ring can be rectified to fit your size with sandpaper placed on a sheet of glass.


    Now, you have to follow the next instructions:

  • Install a piston ring, the expander, after the second piston ring in the lower groove of the piston ring.
  • Install the second compression ring in the middle slot of the piston ring.
  • Install the upper compression ring into the upper groove of the piston ring.

  • Note:

    - Use an annular piston expander to install the piston rings. The rings can be damaged if they expand more than necessary.




    Position the oil rings (2), the grooves of the oil ring rail (3), the second compression ring (4) and the upper compression ring in relation to the notch in the upper part of the piston (1).

    Also, you'll need to lubricate the cylinder wall and piston rings with clean engine oil, and then:

  • Install the piston using a ring compressor and a wooden handle. Guide the end of the lower connecting rod to avoid damaging the crankshaft bearing.
  • Install the connecting rod cap and bearings.
  • Install the bearing bolts on the connecting rod cap. Squeeze in, and tighten the bolts on the connecting rod cap to 25 N · m (18 lb-ft).
  • Use J 45059 or KM-470-B (1) to tighten 1 turn of 30 degrees plus 15 degrees.



  • Finally, install the recovery tube/oil pump, the recovery tube bolts/oil pump. Tighten the bracket bolts and the recovery pump/oil pump to 10 N · m (89 lb in).


    Also, install the crankcase, and the cylinder head with the intake manifold and exhaust manifold fixed.


    And finally, with all these steps you have successfully completed the replacement!

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