Piston, Connecting Rod, and Bearing Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Depressurize the fuel system. Refer to Fuel Pressure Release.
3. Drain the cooling system. Recover the cooling system. Refer to Draining and Filling - Cooling System in Cooling System.
4. Remove the cylinder heads. Refer to Cylinder Head Replacement (Front) or Cylinder Head Replacement (Rear).
5. Remove the oil pan. Refer to Oil Pan Replacement.
6. Mark the piston with the number of the cylinder from which the piston is being removed.
7. Mark the connecting rod and the rod cap so that you can correctly assemble the parts.
8. Turn the crankshaft to bottom dead center.
9. Clean the carbon from the top end of the cylinder.
10. Remove the connecting rod cap.





11. Remove the piston and the rod assembly using a suitable tool.

Installation Procedure

^ Tools Required
- J 8037 Universal Piston Ring Compressor





1. Lubricate the cylinder wall and the piston rings. Use clean engine oil.
2. Turn the crankshaft to bottom dead center.
3. Install the connecting rod stud thread protector.

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





4. Install the J 8037.

Important: Ensure that the arrow on the top of the piston faces towards the front of the engine.





5. Install the piston and the connecting rod assembly.
6. Remove the thread protectors.
7. Install the connecting rod bearing.

Important: Carefully tap the bearing cap into place using a suitable tool. Do not pull the cap down with the cap bolts or the nuts.

8. Seat the bearing caps.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the rod bearing cap nuts.
^ Tighten the rod cap nuts to 20 Nm (15 ft. lbs.). Use the J 36660-A in order to tighten the nuts an additional 75 degrees.
10. Inspect the connecting rod for binding. Pry the rod back and forth using a suitable tool. Loosen the bearing cap if the rod binds. Retighten the bearing cap.
11. Install the oil pan. Refer to Oil Pan Replacement.
12. Install the cylinder head. Refer to Cylinder Head Replacement (Front) or Cylinder Head Replacement (Rear) and Cylinder Head Replacement (Front) or Cylinder Head Replacement (Rear).
13. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
14. Connect the negative battery cable.