Installation

Fig 1: Identifying Piston Ring End Gap Positions

Courtesy of DAIMLERCHRYSLER CORP.

1 - GAP OF LOWER SIDE RAIL

2 - NO. 1 RING GAP

3 - GAP OF UPPER SIDE RAIL

4 - NO. 2 RING GAP AND SPACER EXPANDER GAP

Install piston rings on piston (Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - INSTALLATION)
Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. See Fig 1.
Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in. See Fig 1. As viewed from top.

Fig 2: Installing Piston
Courtesy of DAIMLERCHRYSLER CORP.
Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. See Fig 2. Be sure position of rings does not change during this operation .

Fig 3: Piston Markings
Courtesy of DAIMLERCHRYSLER CORP.

1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA

NOTE: If installing used piston/rod assembly, they must be installed in their original position.
The directional stamp (1) on the piston should face toward the front of the engine. See Fig 3.
Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil.

Fig 4: Connecting Rod Guides
Courtesy of DAIMLERCHRYSLER CORP.

1 - CONNECTING ROD GUIDES 8189
Install connecting rod upper bearing half into connecting rod. Install Connecting Rods Guides 8189 (1) onto connecting rod. See Fig 4.
Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
Remove Connecting Rod Guides 8189.
NOTE: The connecting rod cap bolts should not be reused.
Before installing the NEW bolts, the threads should be coated with clean engine oil.
Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:
CAUTION: Do not use a torque wrench for the second step.
1. Tighten the bolts to 27 N.m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional 1/4 TURN.
Fig 5: Checking Connecting Rod Side Clearance - Typical
Courtesy of DAIMLERCHRYSLER CORP.
Using a feeler gauge, check connecting rod side clearance. See Fig 5. (Refer to ENGINE - SPECIFICATIONS) for connecting rod side clearance.

Install Balance Shaft Carrier Assembly (Refer to BALANCE SHAFT CARRIER under INSTALLATION).

Fig 6: Oil Pan

Courtesy of DAIMLERCHRYSLER CORP.

1 - OIL FILTER

2 - OIL PAN GASKET

3 - OIL PAN

4 - ADAPTER GASKET

5 - OIL FILTER ADAPTER

Install oil pan (3) (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION) .
Install cylinder head (Refer to ENGINE/CYLINDER HEAD - INSTALLATION) .
Start engine and check for leaks.