Cruze

Piston, Connecting Rod, and Bearing Replacement

Special Tools

EN-45059 Angle Meter

For equivalent regional tools, Refer to Special Tools : 1.6L LXT .

1. Open the bonnet.
2. Remove the cylinder head. Refer to Cylinder Head Replacement .
3. Remove the sump. Refer to Sump Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Install the crankshaft pulley bolt.
6. Set the pistons 1 and 4 to TDC in direction of engine rotation.




Note: Observe the cylinder sequence.

7. Mark the connecting rod with the big end bearing cover (1).



8. Remove and DISCARD the 4 connecting rod bearing caps bolts (2) of cylinder 1 and 4.
9. Remove the big end bearing caps (1) and the big end bearing (3).
10. Lower the vehicle.



11. Push the pistons 1 and 4 (1) out of the cylinder bore (2).

Note: The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.

12. Remove the pistons 1 and 4 (1).
13. Turn crankshaft on crankshaft balancer through 180° in direction of rotation of engine.




Note: Observe cylinder sequence.

14. Mark the connecting rod with the big end bearing cover (1).
15. Raise the vehicle.



16. Remove and DISCARD the 4 connecting rod bearing caps bolts (2) of cylinder 2 and 3.
17. Remove the big end bearing caps (1) and the big end bearing (3).
18. Lower the vehicle.



19. Push the pistons 2 and 3 (1) out of the cylinder bore (2).

Note: The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.

20. Remove the pistons 2 and 3 (1).




Note: Observe correct fitting position, observe alignment.

21. Remove the big end bearing (1, 2).
22. Check the components. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .

Note: Lubricate the connection rod bearing with NEW engine oil.

1. Install the big end bearing (1, 2).



2. Set piston ring joints.

•	Piston compression upper ring in position (1).

•	Piston compression lower ring in position (4).

•	Interim ring of the piston oil ring rail in position (5), steel band rings of the piston oil ring rail in position (2) and/or (3).




3. Lubricate the piston rings, piston (1), inner cylinder bore surface and EN-48249 compressor (2) with clean engine oil.




Note: Arrow on piston head points to engine timing side, bead on connecting rod points to transmission side of engine.

4. Push the pistons 2 and 3 (1) into the cylinder bore (2).
5. Raise the vehicle.



6. Install the big end bearing caps (1) and the big end bearing (3).
7. Install 4 NEW big end bearing caps bolts (2) of cylinder 2 and 3 and tighten in 3 passes:

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

7.1.	In first pass tighten to 25 N·m (18 lb ft).

7.2.	In second pass tighten to 30 ° using the EN-45059 meter .

8. Turn crankshaft on crankshaft balancer through 180° in direction of rotation of engine.
9. Lower the vehicle.



10. Push the pistons 1 and 4 (1)into the cylinder bore (2).
11. Raise the vehicle.



12. Install the big end bearing caps (1) and the big end bearing (3).
13. Install the 4 NEW connecting rod bearing caps bolts (2) of cylinder 1 and 4 and tighten in 3 passes:

13.1.

In first pass tighten to 25 N·m (18 lb ft).

13.2.

In second pass tighten to 30 ° using the EN-45059 meter .

14. Set the crankshaft in direction of engine rotation to 60 ° before TDC.
15. Install the crankshaft pulley bolt.
16. Install the oil pan. Refer to Sump Replacement .
17. Install the cylinder head. Refer to Cylinder Head Replacement .
18. Close the bonnet.