Piston and Connecting Rod - Installation

INSTALLATION

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

1. Check piston ring clearance Service and Repair

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

2. Install the piston rings onto the pistons Service and Repair
3. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten the piston ring compressor. Make sure the piston ring position does not change during this procedure.




4. Position the bearing (1) onto the connecting rod.





5. Install special tool 8507 connecting rod guides (1) onto the connecting rod bolt threads.
6. Lubricate the bearing surface with clean engine oil.





7. The pistons are marked by an arrow on the top of the piston indicating installation position. This mark must be pointing toward the front of the engine on both cylinder banks.
8. Wipe the cylinder bore clean and lubricate with clean engine oil.
9. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod guides 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.

CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.





11. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3).
12. Remove special tool 8507 connecting rod guides.

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.
14. Lubricate the new rod bolts with clean engine oil.
15. Install the new and lubricated rod bolts and tighten to 21 Nm (15 ft. lbs.) plus a 90° turn.
16. Install the cylinder head(s) Cylinder Head - Installation
17. Install the timing chain cover Engine Timing Cover(s) - Installation
18. Install the cylinder head covers Cylinder Head Cover(s) - Installation
19. Install the intake manifold Intake Manifold - Installation
20. Install the new oil pan gasket/windage tray and oil pan Engine Oil Pan - Installation
21. Fill the engine with oil Service and Repair