2005/05/09 Pistons and Connecting Rods - Assemble (RENR9703)

SMCS - 1225 i02348194

Assembly Procedure
Required Tools
Tool Part Number Part Description Qty
A 1U-6683 Ring Expander 1
B 1P-1857 Retaining Ring Pliers 1
5P-8639 Hydraulic Press 1
C
5P-8653 Adapter 1

Table 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component

life.

1. The connecting rod controls the piston height above the cylinder block. The
connecting rod and the piston must be assembled and installed in the correct
cylinder. Refer to Testing and Adjusting, "Connecting Rod - Inspect" for the correct
procedure on checking the length of the connecting rod.

Illustration 1 g01165125

2. Use Tooling (C) to install piston pin bushing (6) into connecting rod (7).
Note: Ensure that the oil hole in piston pin bushing (6) is aligned with the oil hole at
the top of connecting rod (7).

3. Machine piston pin bushing (6) in order to obtain a clearance of

0.0330 ± 0.0102 mm (0.00130 ± 0.00040 inch) between piston pin (9) and piston
pin bushing (6).

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 Illustration 2 g00974748

4. The identification Number (Y) that is on the top of the piston must be installed with
the corresponding connecting rod. Position the piston and the connecting rod so
that the identification numbers are located on the same side. The forged Mark (X)
on the connecting rod must be installed on the same side as the Recess (Z) in the
boss for the piston pin. Install piston pin (9) into piston (8) and through connecting
rod (7).
Note: If piston pin (9) cannot be installed by hand, raise the temperature of piston
(8). Do Not use a torch to heat piston (8).

5. Use Tooling (B) in order to install retaining rings (10) that hold piston pin (9) in
position.

6. Use Tooling (A) in order to install piston rings (3), (4), and (5) on piston (8) with the
following steps.

a. Install the oil control ring (5) in the groove that is lowest on the piston. The
latch pin that is on oil control ring (5) must be inside the ends of the spring.
Note: Ensure that the latch pin that is on oil control ring (5) is 180 degrees
from the oil control ring gap.

b. Install the intermediate compression ring (4) with the tapered face into the
second groove on the piston. The stamp "TOP" must be toward the top of the
piston.
Note: Intermediate compression rings that are new have a green mark which
must be on the left of the piston ring gap when the piston ring is installed.

c. Install the top compression ring (3) into the top groove on the piston. The
stamp "TOP" must be toward the top of the piston.
Note: Top compression rings that are new have a red mark which must be on
the left of the ring gap when the ring is installed.

d. Position the piston ring gaps at 120 degrees away from each other.

Illustration 3
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 7. Install upper connecting rod bearing (2) in the connecting rod. Install lower
connecting rod bearing in the connecting rod cap.

8. Repeat Steps 1 through 7 in order to assemble the remaining pistons and

connecting rods.

End By:

a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly,
"Piston and Connecting Rods - Install".

EC31-UP, EC41-UP, EC51-UP, EC61-UP, EC71-UP, EC91-UP, ECL1-UP, GT21-UP,

GT31-UP, GT41-UP, GT51-UP, GT61-UP, GT91-UP, GTH1-UP, L1K1-UP, MMC1-UP,
N3C1-UP, N3X1-UP, N4D1-UP, N4E1-UP, N4R1-UP, N4X1-UP, NCC1-UP, NCD1-UP,
NCE1-UP, PNR1-UP, PR51-UP, PR61-UP, PR91-UP, PRD1-UP, S1M1-UP, SM61-UP,
X3B1-UP, XYC1-UP, XYD1-UP

PSP-000302AA
2021/04/08
16:27:37-05:00
i02334330
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