Piston and Connecting Rod - Installation

INSTALLATION

1. Install piston rings on piston.
2. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Figure 1).
3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in (Figure 1). As viewed from top.
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Figure 2). Be sure position of rings does not change during this operation.




Figure 1 Piston Ring End Gap Position










Figure 2 Piston-Installation

5. The directional stamp on the piston should face toward the front of the engine (Figure 5).
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil.
7. Install connecting rod upper bearing half into connecting rod. Install Special Tool 8189, connecting rod guides onto connecting rod (Figure 4).
8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
9. Remove Special Tool 8189, connecting rod guides.

NOTE: The connecting rod cap bolts should not be reused.

10. Before installing the NEW bolts, the threads should be coated with clean engine oil.
11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:

CAUTION: Do not use a torque wrench for the second step.

- Tighten the bolts to 27 Nm (20 ft. lbs.).
- Tighten the connecting rod bolts an additional 1/4 TURN.

14. Using a feeler gauge, check connecting rod side clearance (Figure 3).




Figure 3 CHECKING CONNECTING ROD SIDE CLEARANCE - TYPICAL

15. Install Balance Shaft Carrier Assembly.
16. Install oil pan.
17. Install cylinder head.





Figure 4 Connecting Rod Guides - Typical


1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES






Figure 5 Piston Markings


1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA