Chevrolet 1980 Light Duty Truck Service Manual page 445

Fig. 6 A 1 -4 3 - M e a s u rin g Ring Groove Clearance
Installation
Cylinder bores must be clean before piston installation.
This may be accomplished with a hot water and detergent
wash or with a light honing as necessary. After cleaning,
the bores should be swabbed several times with light engine
oil and a clean dry cloth.
1. Lubricate connecting rod bearings and install in
rods and rod caps.
2. Lightly coat pistons, rings and cylinder walls with
light engine oil.
3. With bearing caps removed, install Tool J-6305 (11 /
32") on connecting rod bolts.
4. Install each connecting rod and piston in its
respective bore. Pistons must have notches facing front of
Fig. 6 A 1 -4 4 ~ P is ton s -ln sta lle d Position
Fig. 6A1-4 5--ln sta lling Connecting Rod and Piston Assembly
engine (fig. 6A1-44).
Use Tool J-8037 to compress the rings (fig. 6A1-45).
Guide the connecting rod into place on the crankshaft
journal with Tool J-6305 (11/32"). Use a hammer handle
and light blows to install the piston into the bore. Hold the
ring compressor firmly against the cylinder block until all
piston rings have entered the cylinder bore.
5. Remove J-6305.
6. Install the bearing caps and torque nuts to 35 lb. ft.
(47N*m ).
C Y L IN D E R B L O C K
Cleaning and Inspection
1. Wash cylinder block thoroughly in cleaning solvent
and clean all sealing surfaces.
2. Remove oil gallery plugs and clean all oil passages.
3. Clean and inspect water passages in the cylinder
block.
4. Inspect the cylinder block for cracks in the cylinder
walls, water jacket, valve lifter bores and main bearing webs.
5. Measure the cylinder walls for taper, out-of-round
or excessive ridge at top of ring travel. This should be done
with a dial indicator. Set the gage so that the thrust pin must
be forced in about 1/4" (6.5mm) to enter gage in cylinder
bore. Center gage in cylinder and turn dial to "O". Carefully
work gage up and down cylinder to determine taper and
turn it to different points around cylinder wall to determine
the out-of-round condition. If cylinders were found to
exceed specifications, honing or boring will be necessary.
Conditioning
The performance of the following operation is
contingent upon engine condition at time of repair.
If the cylinder block inspection indicated that the block
was suitable for continued use except for out-of-round or
tapered cylinders, they can be conditioned by honing or
boring.
If the cylinders were found to have less than .005" taper
or wear they can be conditioned with a hone and fitted with
the high limit standard size piston. A cylinder bore of less
IN-LINE 6 6A 1-27
LIG H T TR U CK SER V ICE M AN UAL