Rod, Piston And Connecting: Installation

WARNING: This page is about a different variant/trim than selected.

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NOTE:

The fractured connecting rod and rod cap mating surfaces have orientation; they can only be fitted in one position. Furthermore, the connecting rods must be fitted so that the cylinder number stamped above and below the cap joint on the narrow face (edge) of the big end (2) are both located on the same side of the connecting rod big end and on the same side of the piston directional arrow (1). Connecting rods and caps are not mutually interchangeable (cap #1 must stay with connecting rod #1, and so on).

If required, select and fit new pistons 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 .

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NOTE:
Upon disassembly of the connecting rod cap, small particles may be freed from inside of the joint. This is normal. Loose particles must not be trapped within the joint upon reassembly as they prevent proper assembly of the cap to the rod. To ensure loose particles are removed, concentrated air may be blown on the fracture surfaces.
Install the upper half-bearing on the connecting rod (2) with the tang (1) inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.

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Install the (special tool #8189, Guide Pins) (2) on the piston and connecting rod being installed (1).

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Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore.
Install the piston and connecting rod into the cylinder with the piston directional arrow pointing to the front (timing side) of the engine block.

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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)
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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 a piston ring compressor (1) over the piston and rings. Tighten the compressor (1).

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NOTE:
Use care when stuffing piston into cylinder bore. Under no circumstances shall metal tools be used to tap or push piston into the cylinder bore.
Tap the piston down in the cylinder bore using a hammer handle (1) while guiding the connecting rod into position over the rod journal.
Remove the piston ring compressor (2).

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Install the lower half-bearing on the connecting rod cap (1) with the tang (2) inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.

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

NOTE:
Do not lubricate the threads of the connecting rod cap bolts.
Install the connecting rod cap (1) and bearing with the tang on the same side as the rod. Hand-tighten the NEW connecting rod cap bolts (2) evenly to ensure the cap does not bind.
Tighten the connecting rod cap bolts (2) to the proper torque specification. Refer to (TORQUE SPECIFICATION ).
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 connecting rod bearing being replaced.
Install the cylinder head. Refer to INSTALLATION .
Install the windage tray and oil pan. Refer to PAN, OIL, INSTALLATION .