Piston and Piston Pin Installation Procedure
Important: The arrow located on top of the piston must point toward the front
of the engine.
Important: The connecting rod is nondirectional and may be assembled/reassembled
to the piston in either direction.
- Assemble the piston and piston pin to the connecting rod. Properly orient
the piston when reusing a marked connecting rod.
- Align the piston pin bore with the connecting rod pin bore.
- Slide the piston pin (4) into the piston and the connecting rod
(3).
- Install new piston pin retainers (1) by working the retainers
into their grooves until a positive lock is heard and felt.
Important: New piston pin retainers must be used. Never reuse the piston pin retainers.
- Ensure that the piston pin retainers are fully seated in their
grooves.
- Repeat these procedures for the remaining pistons.
Piston Ring Installation Procedure
- Properly orient the oil
control ring expander as shown before installation. The ends of the expander
must be facing toward the top of the piston.
- Using a piston ring expander,
install the oil control ring assembly using the following procedure:
| 2.1. | Install the expander ring (3). |
| 2.2. | Install the two oil scraper rings (4). Expand the rings only enough
to clear the piston diameter. Overexpanding the piston rings will distort
or crack the rings. |
- Install the second and
top piston rings using the piston ring expander. Ensure that you do not overexpand
the rings.
- Once the rings are installed,
set the ring gaps for the oil control, second and top ring as follows. Use
the piston locating arrow for reference.
| 4.1. | Lower oil control ring -- position 1. |
| 4.2. | Upper oil control ring -- position 2 |
| 4.3. | Top Ring -- position 3. |
| 4.4. | Oil control ring expander -- position 4. |
| 4.5. | Second ring -- position 5. |
Connecting Rod Bearing Installation Procedure
Important: If the connecting rod bearings have been used in a running engine, you
must replace them with NEW connecting rod bearings for reassembly.
- Clean the connecting rod and the connecting rod cap bearing bore with
a lint-free cloth.
- Clean all the oil from
behind the connecting rod bearing halves.
- Install new upper connecting rod bearings into position. Roll
the bearing into position so that the lock tang engages the alignment slot.
The bearing must fit flush in the connecting rod.
- Install new lower connecting rod bearings into position in the
connecting rod cap. Roll the bearing into position so that the lock tang engages
the alignment slot. The bearings must fit flush with the connecting rod
cap.
