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Connecting Rod

Engine, Cooling and Exhaust › Engine
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Connecting Rod: Specificationsreference
CONNECTING ROD, ENGINE Tighten connecting rod cap and bearing 27 Nm (20 ft. lbs.) plus 90° CONNECTING ROD Side Clearance 0.10 - 0.35 mm (0.004 - 0.0138 in.) Bearing Bore Out of Round (MAX) 0.004 mm (0.0002 in.) CONNECTING ROD JOURNALS Connecting Rod Journal Diameter 57.908 - 57.892 mm (2.2798 - 2.2792 in.) Out of Round (MAX) 0.005 mm (0.0002 in.)
Procedures — Piston And Connecting Rod - Piston Fitting5 steps
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  1. To correctly select the proper size piston, a cylinder bore gauge (Figure 1) (2), capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
  2. Measure the inside diameter of the cylinder bore (3) at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B.
  3. The coated pistons (Figure 2) (1,2) will be serviced with the piston pin and connecting rod pre-assembled.
  4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston (1,2) will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (.0001 in.) increments is required.
  5. Piston installation into the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.
Procedures — Piston And Connecting Rod - Cleaning2 steps
△ CAUTION
DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged.
△ CAUTION
Do not remove the piston pin from the piston and connecting rod assembly.
  1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry.
  2. Use a wood or plastic scraper to clean the ring land grooves.
Piston And Connecting Rod - Removal6 steps
△ CAUTION
DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur
ℹ NOTE
Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.
△ CAUTION
Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur.
△ CAUTION
Care must be taken not to nick crankshaft journals, as engine damage may occur.
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  1. Disconnect negative cable from battery.
  2. Remove the following components: -Oil pan and gasket/windage tray Engine Oil Pan - Removal. -Cylinder head covers Cylinder Head Cover(s) - Removal and Cylinder Head Cover(s) - Removal. -Timing chain cover Engine Timing Cover(s) - Removal. -Cylinder head(s) Cylinder Head - Removal and Cylinder Head - Removal.
  3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore.
  4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool.
  5. Remove connecting rod cap. Install the Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed.
  6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces.
Piston And Connecting Rod - Installation13 steps
△ CAUTION
Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed.
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  1. Before installing piston and connecting rod assemblies into the bore, install the piston rings.
  2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation.
  3. Position bearing onto connecting rod. Ensure that tabs in bearing shell aligns with slots in connecting rod. Verify that parting line of bearing is aligned with parting line of connecting rod.
  4. Lubricate bearing surface with clean engine oil.
  5. Install Connecting Rod Guides (4) onto connecting rod bolt threads (Figure 1).
  6. The pistons are marked on the piston pin bore surface with an raised "F" indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. The connecting rod oil slinger slot (2) faces the front of the engine (Figure 2).
  7. Wipe cylinder bore clean and lubricate with engine oil.
  8. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal.
  9. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal.
  10. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 27 Nm (20 ft. lbs.) plus 90°.
  11. Install the following components: -Cylinder head(s). Cylinder Head - Installation. -Timing chain and cover. Engine Timing Cover(s) - Installation. -Cylinder head covers Cylinder Head Cover(s) - Installation. -Oil pan and gasket/windage tray. Engine Oil Pan - Installation.
  12. Fill crankcase with proper engine oil to correct level.
  13. Connect negative cable to battery.
Connecting Rod: Description and Operationreference
△ CAUTION
Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl.
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DESCRIPTION The pistons (Figure 1)(2) are made of a high strength aluminum alloy. The connecting rods (1) are made of forged powdered metal, with a "fractured cap" design. A full floating piston pin is used to attach the piston to the connecting rod.