Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPONTIAC19876000 SAFARIREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALMECHANICAL2.8L V6 - VINS [S,W,9]REMOVAL & INSTALLATIONPISTON & ROD ASSEMBLYINSTALLATION
1987 Pontiac 6000 Safari
Piston & Rod Assembly: Installation
1987 Pontiac 6000 SafariSECTION Installation
- Check fit of new piston and rings in cylinder bore before assembling piston and pin to connecting rod. Check piston pin for clearance, etching and wear. New pistons must be installed in the cylinder for which they were fitted. Install used pistons in the cylinder from which they were removed.
- Measure cylinder bore diameter, then measure piston diameter (with rod and pin removed) at skirt across centerline of piston pin. Maximum fitted clearance is .002" (.05 mm) for new pistons and .0024" (.06 mm) for used pistons.
- Oil piston rings and cylinder walls with light coat of oil. Ensure ring gaps are properly spaced and install Ring Compressor (J-8037 or J-8910) on piston. See Figure. Marked side of compression rings must be toward top of piston. Position piston so that identification numbers on rod and cap are on same side.
- Install rubber hose on connecting rod bolts before installing piston and rod assembly in bore. Tap gently with wooden handle to insert piston assembly into cylinder bore.
- After bearings have been inserted, apply engine oil to journals and bearings. Ensure oil hole in bearing insert aligns with oil hole in connecting rod. Turn crankshaft throw to bottom of its stroke. Guide piston and rod assembly over crankshaft journal until rod bearing seats.
- Remove rod bolt protectors. Match rod cap to rod and install. Tighten cap nuts in two steps. Repeat procedure for each piston assembly. After piston and rod assembly is installed, check side clearance of connecting rod on each crankshaft journal.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.