Disassembly and Assembly of Sub-Assemblies

Special Tools:

Disassembly





1. NOTE: Mark the pistons to make sure assembly with the original connecting rods and installation in the same cylinders from which they were removed.

Remove the piston rings from the piston and discard.
1 Remove the two compression rings.
2 Remove the two oil control ring segments and the spacer.





2. WARNING: The retaining ring has a tendency to spring out during removal. Cover the end of the pin bore with a hand or shop rag when removing the retaining ring. Eye protection should be worn. Failure to follow these instruction may result in personal injury.

Using the special tool to remove the two piston pin retaining rings.
3. Push the piston pin from the piston and connecting rod.

Assembly
1. Clean and inspect the piston and connecting rod.





2. NOTE: Check each end of the piston ring for an identification mark. If present, install the piston pin with the identification mark toward the front of the engine.

Install a new piston pin retaining ring into one side of the piston pin bore.





3. Lubricate and start the piston pin in the piston and connecting rod.
4. Push the-piston pin through the piston until it bottoms on the retaining ring.





5. Install a new piston pin retaining ring on the opposite side of the piston pin bore.
- Make sure that the connecting rod moves freely after assembly.





6. NOTE: Install piston rings from the top side of piston. Avoid scratching the Teflon coating on the piston skirts if present.

NOTE: Assemble the lower compression ring with the scraper groove down.

NOTE: Position the oil control ring spacer so the cut ends are pointed toward the piston dome.

Install the piston rings.
1 Install the two oil control ring segments and spacer.
2 Use a piston ring expander and install the two, compression rings.
7. Check the end gap of all piston rings.





8. Position the compression rings, oil control rings and expander gaps.
1 Position the oil control segment ring gap.
2 Position the expander ring and lower compression ring gaps.
3 Position the upper compression ring gap.