Rod, Piston And Connecting: Installation
WARNING: This page is about a different variant/trim than selected.
- If required, select and fit new piston and connecting rod assemblies to the engine block. Refer to ENGINE/ENGINE BLOCK/ROD, PISTON AND CONNECTING - STANDARD PROCEDURE .
- If required, select and fit new bearings to the connecting rod. Refer to ENGINE/ENGINE BLOCK/BEARING(S), CONNECTING ROD - STANDARD PROCEDURE .
- If required, hone the cylinder bores. Refer to ENGINE/ENGINE BLOCK - STANDARD PROCEDURE .
- If removed, install the piston rings. Refer to INSTALLATION .
- Position the piston ring end gaps as follows:
- Oil ring expander gap (5)
- Oil ring lower side rail end gap (4)
- Oil ring upper side rail end gap (1)
- No. 2 (intermediate) ring end gap (5)
- No. 1 (upper) ring end gap (2)
NOTE:Typical I4 engine configuration shown in illustration.
NOTE:Ensure the position of the ring end gaps does not change when installing the ring compressor.
- Lubricate the piston rings with clean engine oil. Position Piston Compressor (special tool #C-385, Compressor, Piston) (2) over the piston and rings. Tighten the compressor (2).NOTE:
Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an old bearing half.
- Install the bearing shell (7) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
- Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod being installed.
- The pistons crowns are stamped with an arrowhead (1) indicating installation position. This mark must be positioned toward the front of engine.
- Wipe the cylinder bore clean and lubricate with clean engine oil.
- Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore.CAUTION:
Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.
- Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
- Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting rod into position over the rod journal.NOTE:
Typical I4 engine configuration shown in illustration.
CAUTION:The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
- Install the bearing shell (5) on the connecting rod cap (3) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.NOTE:
Do not lubricate the threads of the connecting rod cap bolts (4).
- Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW connecting rod cap bolts (4) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
- If required, check the connecting rod side clearance. Refer to ENGINE/ENGINE BLOCK/ROD, PISTON AND CONNECTING - STANDARD PROCEDURE .
- Repeat the previous steps for each piston being installed.
- Install the ladder frame, balance shaft module and oil pan. Refer to FRAME, LADDER, INSTALLATION .
- Install the cylinder head and engine timing cover. Refer to INSTALLATION .
- If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE .
- Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
- Fill the cooling system. Refer to 2.4L COOLANT FILL .
- Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to ADDING ADDITIONAL COOLANT .