Piston & Rod Assembly

TOOL REQUIRED
J 41507 Connecting Rod Guide
J 36660 Torque Angle Meter
J 8037 Piston Ring Compressor





REMOVAL
1. Disconnect the negative battery cable.
2. Remove the cylinder head.
3. Remove the oil level sensor.
4. Remove the oil pan.
5. Remove the oil pump pipe and screen.

CAUTION: In order to avoid damage to the piston ring lands, be sure to remove any carbon or ridge at the top of the cylinder bore.

6. Mark the connecting rod cap and rod for proper reassembly.
7. Remove the connecting rod bolts.
8. Remove the connecting rod cap.
9. Install Connecting Rod Guide to the connecting rod assembly. The Connecting Rod Guide must be hand-tightened securely to the connecting rod.
10. Using hand pressure on Connecting Rod Guide, push the connecting rod assembly towards the top of the cylinder.
11. Remove the piston and connecting rod assembly.
12. Remove the Connecting Rod Guide.

INSTALLATION

CAUTION: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.

1. Install the piston rings to the piston. In order to provide an effective compression seal, stagger the ring gaps.
2. Turn the crankshaft to bottom dead center.
3. Lubricate the cylinder with oil.
4. Install the connecting rod bearing.
5. Install the piston and the connecting rod assembly with the ridges toward the front of the engine. Use the Piston Ring Compressor.
6. Raise the vehicle. Suitably support the vehicle.

CAUTION: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.

7. Use the Connecting Rod Guide in order to guide the connecting rod through the cylinder.
8. Remove Connecting Rod Guide.
9. Install the connecting rod cap.

CAUTION: This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.

10. Install the connecting rod cap bolts. Tighten the bolts to 27 Nm (20 ft. lbs.). Use the Torque Angle Meter in order to rotate the bolts an additional 50 degrees.
11. Install the oil pump pipe and screen assembly.
12. Install the oil pan.
13. Install the oil level sensor.
14. Install the cylinder head.
15. Connect the negative battery cable.