Piston And Connecting Rod - Installation

INSTALLATION

Special Tools:











NOTE: Before reinstalling used rings or installing new rings, the ring clearances must be checked.

NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.

1. Check piston ring clearance Service and Repair.
2. Before installing piston and connecting rod assemblies into the bore, install the piston rings Service and Repair.
3. Immerse the piston head and rings in clean engine oil and position a ring compressor over the piston and rings and tighten the ring compressor. Ensure the position of rings do not change during this operation.
4. Position the rod bearing (1) onto the connecting rod and lubricate bearing surface with clean engine oil.





5. Install Connecting Rod Guides (1) into the connecting rod bolt threads.





6. The pistons are marked on the piston pin bore surface with an raised "F" or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
7. Wipe cylinder bore clean and lubricate with clean engine oil.
8. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore.
9. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod over the crankshaft journal.
10. Tap the piston down into the cylinder bore using a hammer handle while guiding the connecting rod into position on the rod journal.





11. Remove the Connecting Rod Guides.
12. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3).

NOTE: The connecting rods and bearing caps are not interchangeable, line up the previously marked bearing caps and connecting rods to ensure assembly to their original location.

13. Lubricate the bearing surfaces with clean engine oil and position the rod cap in place.






CAUTION: When installing the connecting rods, make sure the wide side of the connecting rod faces the crankshaft and the narrow sides face each other.





CAUTION: Always replace the connecting rod bolts whenever they are loosened or removed.

14. Lubricate the new rod cap bolts with clean engine oil, install and tighten to 21 Nm (15 ft. lbs.) plus 90°.
15. Install the timing chain cover Engine Timing Cover(s) - Installation.
16. Install the new oil pan gasket/windage tray and oil pan Engine Oil Pan - Installation.
17. Install the engine oil dipstick tube and dipstick.
18. Lower the vehicle.
19. Using the Engine Lift Fixture (1), Engine Lift Adapter (2) and the Engine Support Fixture (3) lower the engine into position and remove.
20. Raise and support the vehicle.





21. Position the steering gear (2), install mounting bolts (1) and tighten to 95 Nm (70 ft. lbs.).





22. Install the engine mount nuts (1,2) and tighten to 95 Nm (70 ft. lbs.).
23. Lower the vehicle.
24. Install the cylinder head(s) Cylinder Head - Installation.





25. Position the air cleaner housing (2), install the air cleaner housing retaining bolt (3) and securely tighten.
26. Connect the makeup air hose (1).
27. Connect the intake air temperature sensor (4) electrical connector.
28. Connect the air duct to the throttle body and tighten clamp to 3 Nm (30 in. lbs.).
29. Fill the engine with oil Service and Repair.





30. Install the engine covers (1).





31. Connect the negative battery cable (3).