Piston & Rod Assembly

TOOL REQUIRED
^ J 8037 Universal Piston Ring Compressor
^ J 36660 Torque Angle Meter

REMOVAL
1. Depressurize the fuel system. See Powertrain Management.
2. Disconnect the negative battery cable.
3. Drain the cooling system. Recover the cooling system. See Cooling System.
4. Remove the cylinder head.
5. Remove the oil pan.
6. Mark the piston with the number of the cylinder from which it is being removed.
7. Mark the connecting rod and the rod cap so that they can be assembled correctly.
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.

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

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





4. Install the Universal Piston Ring Compressor.

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





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

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

8. Seat the bearing caps.
9. Install the rod bearing cap nuts. Tighten the rod cap nuts to 20 Nm (15 lb ft). Use the Torque Angle Meter in order to tighten the nuts an additional 75 degrees.
10. Check the connecting rod for binding. Pry the rod back and forth with a suitable tool. Loosen the bearing cap if the rod binds. Retighten the bearing cap.
11. Install the oil pan.
12. Install the cylinder head.
13. Fill the cooling system. See Cooling System.
14. Connect the negative battery cable.