GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Impala 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Piston, Connecting Rod, and Bearing Installation

Tools Required

    • J 36660-A Torque Angle Meter
    • J 8037 Piston Ring Compressor
    • J 41507 Connecting Rod Guide Assembly
  1. Position the crankshaft so the connecting rod journal is opposite the piston and connecting rod assembly being installed. This will aid in the installation of the connecting rod assembly.
  2. Lubricate the cylinder wall with engine oil.
  3. Install the connecting rod bearing inserts.
  4. Lubricate the connecting rod bearing insert surface with engine oil.

    5. Object Number: 38180 Size: SH
  5. Install J 41507 to the connecting rod. Hand tighten the tool to the connecting rod.
  6. Install J 8037 to the piston.

    7. Notice: Guide the lower connecting rod end carefully to avoid damaging the crankshaft journal.


    Object Number: 5159 Size: SH
  7. Use J 8037 to compress the piston rings for installation of the piston and connecting rod assembly.
  8. Install the piston and connecting rod assembly into the engine.

    9. Important:: Ensure the arrow on top of the piston or the markings made during removal face towards the front of the engine or are in the same location as when removed.

  9. Use J 41507 to pull the connecting rod into place.
  10. Remove J 41507 .

    11. Object Number: 38153 Size: SH
  11. Install the connecting rod bearing cap.

    12. Notice: Refer to Special Fastener Notice in the Preface section.

    Notice: 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.

  12. Install the connecting rod bearing cap bolts.

    13. Tighten
    Tighten the connecting rod bearing cap bolts to 27 N·m (20 lb ft) + 50 degrees using J 36660-A .

  13. Pry the connecting rod back and forth and check for binding. If necessary loosen and retighten the connecting rod bearing cap.

    14. Object Number: 5163 Size: SH
  14. Measure the connecting rod side clearance.