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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 995 (Engine Mechanical - 8.1L) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Piston, Connecting Rod, and Bearing Installation >> Piston Installation

Piston Installation

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Coat the following components with clean engine oil:
    • The piston
    • The piston rings
    • The cylinder bore
    • The bearing surfaces
  2. Install rubber fuel line onto the connecting rod bolts.
    3. Fig 1: View Of Rubber Fuel Line From Connecting Rod Bolts
    GM639532Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The mark on the top of the piston must face the front of the engine block. When assembled, the flanges on the connecting rod and cap should face to the front of block on the left bank and to the rear of block on the right bank.
  3. Install the piston, connecting rod and upper connecting rod bearing through the top of the engine block.
    4. Fig 2: View Of Piston, Connecting Rod, & Connecting Rod Upper Bearing
    GM639536Courtesy of GENERAL MOTORS CORP.
  4. Install the J 8037  onto the piston and compress the piston rings.
  5. Use the J 8037  and lightly tap the top of the piston with a wooden hammer handle.
  6. Hold the J 8037  firmly against the engine block until all of the piston rings have entered the cylinder bore.
    7. Fig 3: Installing Piston & Connecting Rod Assembly Into Engine
    GM5159Courtesy of GENERAL MOTORS CORP.
  7. Use the rubber fuel line in order to guide the connecting rod onto the crankshaft journal.
  8. Remove the rubber fuel line.
    9. Fig 4: Installing Rubber Fuel Line Onto Connecting Rod Bolts
    GM639533Courtesy of GENERAL MOTORS CORP.
  9. Install the connecting rod cap and lower connecting rod bearing.
    10. NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: When installing the piston/connecting rod assembly, NEW connecting rod nuts must be installed.
  10. Install the new connecting rod nuts.

    Tighten: 

    1. Tighten the connecting rod nuts a first pass to 30 N.m (22 lb ft).
    2. Tighten the connecting rod nuts a final pass 90 degrees using the J 45059  .

    11. Fig 5: View Of Connecting Rod Cap & Connecting Rod Lower Bearing
    GM639084Courtesy of GENERAL MOTORS CORP.
  11. Once the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to make sure that they have side clearance.
  12. Use a feeler gage or a dial indicator to measure the side clearance between the connecting rod caps. The rod side clearance should be 0.384-0.686 mm (0.0151-0.0270 in).
    13. Fig 6: Measuring Connecting Rod Side Clearance Using J 7872
    GM677801Courtesy of GENERAL MOTORS CORP.
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