LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1354 (Engine Mechanical - 4.8L, 5.3L & 6.0L) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Piston, Connecting Rod, and Bearing Installation >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and connecting rod assembly into the proper cylinder bore.

The piston alignment mark MUST face the front of the engine block.

  1. Lightly lubricate the following components with clean engine oil:
    • The piston
    • The piston rings
    • The cylinder bore
    • The bearing surfaces
  2. Stagger the oil control ring end gaps a minimum of 90 degrees.
    Fig 1: Piston, Rings, Cylinder Bore & Bearing
    G02107201Courtesy of GENERAL MOTORS CORP.
  3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
  4. Install the J 41556  to the connecting rod.
  5. Install the J 8037  onto the piston and compress the piston rings.
    IMPORTANT: The piston alignment mark MUST be facing the front of the engine block.
  6. Install the piston and connecting rod assembly into the proper cylinder bore.
    1. 6.1. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
    2. 6.2. Use the J 41556  to guide the connecting rod end onto the crankshaft journal.
    Fig 2: Compress Piston Using J 8037
    G02107202Courtesy of GENERAL MOTORS CORP.
  7. Remove the J 41556  .
    Fig 3: Remove J 41556
    G02107203Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
    IMPORTANT: Position the connecting rod cap onto the connecting rod properly.

    Align the flat side of the connecting rod cap with the flat side of the connecting rod.

  8. Install the bearing, cap, and bolts.

    Tighten 

    1. 8.1. Tighten the bolts a first pass evenly to 20 N.m (15 lb ft).
    2. 8.2. Tighten the bolts a final pass to 75 degrees using the J 36660-A  .
    Fig 4: Installing Bearing, Cap & Bolts
    G02107204Courtesy of GENERAL MOTORS CORP.
  9. Inspect the connecting rods for proper orientation onto the crankshaft journal.
  10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
  11. Measure the connecting rod side clearance using a feeler gage or a dial indicator. Connecting rod side clearance should be within 0.11-0.51 mm (0.0043-0.02 in).
    Fig 5: Inspecting Connecting Rods For Proper Orientation
    G02107205Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals