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Rod, Piston And Connecting: Installation: Installation

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Piston Ring End Gap Position
GC0095425Courtesy of CHRYSLER GROUP, LLC
  1. If required, select and fit new piston and connecting rod assemblies to the engine block. Refer to STANDARD PROCEDURE .
  2. If required, hone the cylinder bores. Refer to STANDARD PROCEDURE .
  3. If removed, install the piston rings. Refer to RING(S), PISTON, INSTALLATION .
  4. Position the piston ring end gaps as follows:
    • Oil control ring expander gap (5)
    • Oil control ring end gap (2)
    • No. 2 (intermediate) ring end gap (4)
    • No. 1 (upper) ring end gap (1)
    Fig 2: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Make sure the position of the ring end gaps does not change when installing the ring compressor.

  5. Lubricate the piston rings with clean engine oil. Position the (special tool #C-385, Compressor, Piston) (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.

  6. Install the bearing shell (7) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
  7. Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod.
    Fig 3: Arrowheads Stamped On Pistons Crowns
    GC0152770Courtesy of CHRYSLER GROUP, LLC
  8. The pistons crowns are stamped with an arrowhead (1) indicating installation position. The arrowhead must point toward the front of engine.
  9. Wipe the cylinder bore clean and lubricate with clean engine oil.
  10. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
  11. Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting rod into position over the rod journal.
    Fig 4: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

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

  12. Install the bearing shell (5) on the connecting rod cap (3) 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 (4).

  13. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW  connecting rod cap bolts (4) to 20 N.m (15 ft. lbs.) plus 40 degrees.
  14. If required, check the connecting rod side clearance. Refer to STANDARD PROCEDURE .
  15. Repeat the previous steps for each piston being installed.
    Fig 5: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  16. Install the oil pump pick-up and oil pan. Refer to PICK-UP, OIL PUMP, INSTALLATION .
  17. Install the cylinder head, timing belt and sprockets. Refer to CYLINDER HEAD, INSTALLATION .
  18. Install the engine. Refer to INSTALLATION .
  19. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  20. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  21. Fill the cooling system. Refer to STANDARD PROCEDURE .
  22. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
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