Piston And Connecting Rod - Installation

INSTALLATION

Special Tools:

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

CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur.

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

NOTE: The pistons are marked on the piston pin bore surface with an raised "F" or an arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.

5. Wipe the cylinder bore clean and lubricate with clean engine oil.
6. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore. Insert rod and piston assembly into the cylinder bore and carefully position connecting rod guides over crankshaft journal.
7. Tap the piston down into the cylinder bore using a hammer handle. While guiding the connecting rod into position on the rod journal.
8. Remove the connecting rod guides.

9. Wipe the connecting rod cap clean and install the rod bearing.

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

10. Lubricate the bearing surfaces with clean engine oil and install the bearing and connecting rod cap onto the connecting rod journal in the same position as noted during removal.
11. Lubricate the new connecting rod bolts with clean engine oil and install the bolts finger tight.
12. Tighten the connecting rod bolts to 21 Nm (15 ft. lbs.) plus a 90° turn.

13. If required, measure the connecting rod side clearance Engine Specifications.
14. Repeat the previous steps for each piston and connecting rod assembly being installed.

15. Clean the oil pan gasket mating surface of the block and oil pan.

NOTE: When the oil pan is removed, a new oil pan gasket and pickup tube O-ring must be installed. The old gasket and O-ring cannot be reused.

16. Install a new oil pan gasket and pickup tube O-ring.

NOTE: Mopar(R) Engine RTV must be applied to the 4 T-joints (1,2) area where the front cover, rear retainer and oil pan gasket meet. The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations.

17. Apply Mopar(R) Engine RTV at the T- joints (1,2).

18. Position the oil pan, install the mounting bolts and using the sequence shown, tighten to 12 Nm (9 ft. lbs.).
19. Install the engine oil dipstick.

Right cylinder head gasket shown, left cylinder head gasket similar.

CAUTION: The cylinder head gaskets are not interchangeable between the left and right sides. They are marked with an "L" and "R" to indicate the left or right side and they are marked "TOP" to indicate which side goes up.

20. Using a suitable solvent, clean all sealing surfaces of the cylinder block and cylinder heads.
21. Position the new cylinder head gasket(s) (5) onto the cylinder block.
22. Position the cylinder head(s) (4) onto the cylinder head gasket (5) and cylinder block.

Right cylinder head shown, left cylinder head similar.
23. Using the sequence shown, tighten the cylinder head bolts 1 through 10 to 34 Nm (25 ft. lbs.).
24. Using the sequence shown, tighten the cylinder head bolts 11 through 15 to 20 Nm (15 ft. lbs.).
25. Again using the sequence shown, tighten the cylinder head bolts 1 through 10 to 54 Nm (40 ft. lbs.).
26. Again using the sequence shown, tighten the cylinder head bolts 11 through 15 to 20 Nm (15 ft. lbs.).
27. Again using the sequence shown, rotate the cylinder head bolts 1 through 10 90°.
28. Again using the sequence shown, tighten the cylinder head bolts 11 through 15 to 34 Nm (25 ft. lbs.).

Right cylinder head shown, left cylinder head similar.

CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side.

29. Install the pushrods in the same position as noted during removal.
30. Install the pushrod retainer (1).

CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result.

CAUTION: Verify the pushrod(s) are installed into the rocker arm(s) (2) and the tappet(s) correctly while installing the rocker shaft assembly (3) or engine damage could result. Recheck after the rocker shaft assembly has been tightened to specification.

CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2).

31. Install the rocker shaft assemblies in the same position as noted during removal.
32. Using the sequence shown, tighten the rocker shaft bolts to 22 Nm (16 ft. lbs.).

CAUTION: Do Not rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about five minutes).

33. Remove the pushrod retainer (1).

NOTE: The cylinder head cover gasket (1) may be used again, provided no cuts, tears, or deformation have occurred.

34. Inspect the cylinder head cover gasket (1), replace if necessary.

CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur.

35. Clean the cylinder head cover (2) and the cylinder head sealing surface.
36. Apply Mopar(R) Lock & Seal Adhesive to the cylinder head cover bolts.
37. Position the cylinder head cover and gasket, install the retaining bolts finger tight.

38. Using the sequence shown, tighten the cylinder head cover bolts to 8 Nm (70 in. lbs.).

NOTE: Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots.

39. Install the ignition coils (2).
40. Install the ignition coil retaining bolts (3) and tighten to 7 Nm (62 in. lbs.).
41. Install the engine into the vehicle Engine - Installation.

42. Connect negative cable to battery.

43. Install the engine cover (2).
44. Fill the engine with the proper engine oil .
45. Install the oil fill cap (1).
46. Fill the cooling system with the proper coolant Service and Repair.
47. Start the engine and check for leaks.
48. Road test the vehicle.