GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL 🢒 Engine 🢒 Engine Mechanical - 1.9L 🢒 Piston and Connecting Rod Assemble

Tools Required

SA9101E Piston Pin Retainer/Replacer


    Object Number: 871296 Size: SH
  1. Assemble piston and connecting rod:

    2. Important: It is standard practice to assemble the piston and connecting rod with bearing tang slots in the rod directed toward the exhaust manifold side.

  2. Align the mark on top of the piston with the front of the engine. Assemble the connecting rod to the piston with the bearing tang slots directed toward the exhaust manifold side.

    3. Object Number: 877263 Size: SH

    Notice: Carefully remove any burrs in the piston bore, next to the snap ring groove, using an X-ACTO knife (or equivalent). This will prevent piston pin scoring during removal.

  3. Coat the piston pin with engine oil.
  4. Install the piston pin using the SA9101E .

    5. Object Number: 871300 Size: SH
  5. Check that the piston and connecting rod moves smoothly back and forth on the piston pin.

    6. Object Number: 877267 Size: SH
  6. Install the retainer in the SA9101E cone with the ring's open ends directed away from the tools slotted opening. Set the cone on it's base and push the snap ring down through the cone until seated with the driver.

    7. Important: Snap ring cone SA9101E must be used with 2000 and later model year pistons. This is the snap ring cone used in 1994 and earlier years.

  7. Lay the piston on a clean block of wood. Position the cone with snap ring and driver over the piston pin hole with the cone's slotted opening facing toward the top of the piston. Firmly push the driver downward until the retainer is seated in the snap ring groove.

    8. Object Number: 873007 Size: SH
  8. Install the piston rings:
  9. Install the oil ring expander and 2 side rails by hand.

    10. Object Number: 871312 Size: SH
  10. Using a piston ring expander, install the two compression rings.

    11. Object Number: 871312 Size: SH

    Important: The top ring is thinner than the second ring. The top ring is symmetrical and can be installed with either side up. The second ring has a pip mark which must be installed with the pip mark up.

  11. The second ring has a pip mark which must be installed with the pip mark up.

    12. Object Number: 873009 Size: SH

    Important: Do not align the ring gaps. Each ring should be rotated 90-120 degrees from each other around the piston.

  12. Each ring should be rotated 90-120 degrees from each other around the piston.

    13. Object Number: 871317 Size: SH
  13. Install bearings:

    14. Install the upper bearing in the connecting rod. Apply a small amount of oil to the bearing surfaces and piston rings.