Piston And Connecting Rod - Installation

INSTALLATION

Special Tools:






CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler must be replaced or damage to the new engine and/or components could result.






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. 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 the engine on both cylinder banks.
6. Wipe the cylinder bore clean and lubricate with clean engine oil.
7. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore.
8. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod over the crankshaft journal.
9. Tap the piston down in cylinder bore using a hammer handle. While at the same time, guide the connecting rod into position on crankshaft rod journal.





10. 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.

11. Lubricate the bearing surfaces with clean engine oil and position the rod cap onto the connecting rod.

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.





12. Verify the connecting rods are properly installed, the wide side (1) of the connecting rod is facing towards the crankshaft and the narrow sides (2) of the connecting rods face each other.
13. Lubricate the new rod cap bolts with clean engine oil, install and tighten to 45 Nm (33 ft. lbs.) plus an additional 60° turn.

CAUTION: When removing and installing the pistons and connecting rods, do not damage the piston oil cooler jets. If the jets are bent, engine damage may occur.





14. Position the piston oil cooler jet(s) (1).
15. Install the piston oil cooler jet retaining bolt(s) (2) and tighten to 13 Nm (10 ft. lbs.).





16. Install the new oil pan gasket/windage tray (3), oil pump pickup tube (2) 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.






NOTE: Left side shown, right side similar.

20. Install both left/right engine mount lower retaining bolts (2) and tighten to 68 Nm (50 ft. lbs.).
21. Position both left/right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 Nm (20 ft. lbs.).





22. Install the engine timing cover Engine Timing Cover(s) - Installation.
23. Raise and support the vehicle.





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





25. Position the belly pan and install the belly pan retainers (1).
26. Lower the vehicle.





27. Install the cylinder head(s) Cylinder Head - Installation.
28. Install the intake manifold Intake Manifold - Installation.





29. While sliding the air duct onto the throttle body, lower the air cleaner housing (5) into position and align the locating pin on the bottom of the housing.
30. Install the air cleaner housing retaining bolt (4) and tighten to 5 Nm (44 in. lbs.).
31. Install the makeup air hose (3) at the air cleaner housing.
32. Connect the intake air temperature sensor electrical connector (2).
33. Position the air duct retaining clamp (1) at the throttle body and tighten to 3 Nm (30 in. lbs.).
34. Fill the cooling system with the specified type and amount of engine coolant Service and Repair.
35. Fill the crankcase with the specified type and amount of engine oil Service and Repair.





36. Install the engine covers (1).





37. Connect the negative battery cable (3).
38. Start the engine and check for leaks.