Connecting Rod: Service and Repair

Piston, Connecting Rod, and Bearing Replacement

Special Tools
* J-8037 - Ring Compressor
* J-24270 - Cylinder Bore Ridge Reamer
* J-43966-1 - Connecting Rod Guides
* J-45049 - Angle Meter

Removal Procedure

1. Remove the oil pan. Refer to Oil Pan Replacement (Service and Repair).
2. Remove the cylinder head. Refer to Cylinder Head Replacement (Service and Repair).




3. If a ring ridge is present, use J-24270 - reamer to remove the ring ridge as follows:

1. Turn the crankshaft until the piston is at the bottom of the stroke.
2. Place a cloth on top of the piston.
3. Use a ridge reamer to remove the ring ridge.
4. Turn the crankshaft so the piston is at top of the stroke.
5. Remove the cloth and cutting debris.





Note: Place the numbers on connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods.

4. Remove the connecting rod nuts and the connecting rod cap.
Discard the bolts and nuts.




5. Remove the connecting rod and the piston out of the top of the engine block using the J-43966-1 - guides.
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

Installation Procedure

1. Coat the following parts with engine oil:

* The piston
* The piston rings
* The cylinder bore
* The bearing surfaces




2. Install the piston into its original bore using the J-43966-1 - guides.




3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the J-8037 - compressor firmly against the engine block until all the piston rings have entered the cylinder bore.
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.

Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the new connecting rod bolts and nuts.

1. On the first pass, tighten the nuts evenly to 25 Nm (18 lb ft).
2. On the final pass, use the J-45049 - meter in order to tighten the nuts an additional 100 degrees.




9. Measure the connecting rod side clearance with a feeler gauge.
The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to Cylinder Head Replacement (Service and Repair).
11. Install the oil pan. Refer to Oil Pan Replacement (Service and Repair).