Piston And Connecting Rod - Installation
INSTALLATION
Special Tools:
1. If required, select and fit new piston and connecting rod assemblies to the engine block Piston Fitting
2. If required, select and fit new bearings to the connecting rod Procedures
3. If required, hone the cylinder bores Cylinder Bore Honing
4. If removed, install the piston rings Piston Ring(s) - Installation.
5. 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 V6 engine configuration shown.
NOTE: Ensure the position of the ring end gaps does not change when installing the ring compressor.
6. Lubricate the piston rings with clean engine oil. Position Piston Compressor (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.
7. Install the bearing shell (8) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
8. Remove the plastic guide plates (3) from the Guide Pins (7) and install the Guide Pins to the connecting rod being installed.
NOTE: Right cylinder bank shown, left cylinder bank similar.
9. The pistons crowns are stamped with a mark (1) indicating installation position. This mark must be positioned toward the front of engine on both cylinder banks.
10. Wipe the cylinder bore clean and lubricate with clean engine oil.
11. 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.
12. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
13. 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 V6 engine configuration shown.
CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.
14. Install the bearing shell (6) on the connecting rod cap (4) 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 (5).
15. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the the NEW connecting rod cap bolts (5) to 20 Nm (15 ft. lbs.) plus 90°.
16. If required, check the connecting rod side clearance Measuring Connecting Rod Side Clearance
17. Repeat the previous steps for each piston being installed.
CAUTION: The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.
18. Check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
19. Install the windage tray with eight main bearing cap bolts. Tighten the bolts in the sequence shown to 21 Nm (16 ft. lbs.) plus 90°.
20. Install the engine oil pump and oil pump pick-up Engine Oil Pump - Installation
21. Install the cylinder heads, engine timing cover and oil pans Cylinder Head - Installation
22. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair
23. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
24. Fill the cooling system Service and Repair.
25. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair