Connecting Rod: Service and Repair
PISTON & CONNECTING RODREMOVAL
1. Disconnect negative cable from battery.
2. Remove the following components:
Oil pan and gasket/windage tray.
Cylinder head covers.
Timing chain cover.
Cylinder head(s).
3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur
NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool.
CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.
CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur
CAUTION: When removing and installing the piston and connecting rod assembly, Do not damage the piston cooling jets. If the jets are bent, engine damage may occur.
6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
7. Carefully remove piston rings from piston(s), starting from the top ring down.
CLEANING
CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged.
1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.
INSPECTION
Check the connecting rod journal for excessive wear, taper and scoring.
Check the connecting rod for signs of twist or bending.
Use the proper tool when removing the piston clip. If the clip is pried out, a burr may form on the groove that will inhibit pin removal and installation.
Check the piston for taper and elliptical shape before it is fitted into the cylinder bore.
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
1. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil.
4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads.
5. The pistons are marked on the piston pin bore surface with an raised "F or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks.
6. Wipe cylinder bore clean and lubricate with engine oil.
7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal.
CAUTION: Always replace the Rod Bolts whenever they are loosened or removed.
9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 45 Nm (33 ft. lbs.) plus a 60° turn.
10. Install the following components: Cylinder head(s). Cylinder head covers. Install the intake manifold. Oil pan and gasket/windage tray.
11. Fill crankcase with proper engine oil to correct level.
12. Connect negative cable to battery.