Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Apply clean engine oil to the following components:
- The piston
- The piston rings
- The cylinder bore
- The bearing surfaces
Install the J 5239 onto the connecting rod bolts.

Fig 1: Installing J 5239 Onto Connecting Rod Bolts
Courtesy of GENERAL MOTORS CORP.
Install the J 8037 onto the piston and compress the piston rings.

Fig 2: Installing J 8037 Onto Piston
Courtesy 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 connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.
Install the piston and connecting rod assembly, and the J 8037 into the proper cylinder bore.

Fig 3: Installing Piston & Connecting Rod Assembly & J 8037 Into Proper Cylinder Bore
Courtesy of GENERAL MOTORS CORP.
Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle.
1. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.
2. Use the J 5239 in order to guide the connecting rod onto the crankshaft journal.
  
  Fig 4: Using J 8037 & J 5239 & Tapping Top Of Piston With Wooden Hammer Handle
  Courtesy of GENERAL MOTORS CORP.
Remove the J 5239 .

Fig 5: Removing J 5239
Courtesy of GENERAL MOTORS CORP.

CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the connecting rod caps, bearings, and nuts.
Tighten
1. Tighten the nuts evenly on the first pass to 27 N.m (20 lb ft).
2. Use the J 36660-A in order to tighten the nuts on the final pass an additional 70 degrees.
  
  Fig 6: Installing Connecting Rod Caps, Bearings & Nuts
  Courtesy of GENERAL MOTORS CORP.
After the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to ensure that the connecting rods have side clearance.
Use a feeler gage or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15-0.44 mm (0.006-0.017 in).

Fig 7: Measuring Connecting Rod Side Clearance
Courtesy of GENERAL MOTORS CORP.