Service Manual

5.52
ENGINE
Piston / Connecting Rod Assembly
1. Lubricate connecting rod small end, piston pin bore, and
piston pin with engine oil.
2. Install a new circlip on one side of piston with gap UP (at
the 12:00) or DOWN (at the 6:00) position.
NOTE: If re-installing connecting rods, orient the
marks on rod caps the same as when removed. Be
aware of this direction when installing pistons to
rods. If new connecting rods are being installed,
they can be installed either way (there is no piston
pin offset in the rod) however it is recommended
they be installed with marks on both rods facing the
same direction.
3. Place piston on connecting rod so arrow on crown of piston
points toward MAG end of crankshaft (water pump end).
4. Push piston pin through rod and piston until it seats against
the installed circlip.
IMPORTANT: Do not tap on pin or cause any sideways
force to connecting rod. Warm piston crown with a
heat gun if pin cannot be installed by hand, or use a
piston pin installation tool. DO NOT apply heat
directly to piston rings or a loss of radial tension could
result.
5. Install the remaining circlip with gap at the top or bottom.
Push the piston pin in both directions to make sure the clips
are properly seated in the groove.
IMPORTANT: Never re-use a circlip that has been
installed.
6. Check to be sure rings rotate freely in the grooves.
Piston / Connecting Rod Installation
1. Apply clean engine oil to piston assembly and cylinder
walls of upper crankcase.
2. Be sure ring end gaps are positioned at least 120 degrees
apart as shown below. Oil ring rails at least 60 degrees
apart. (See “Piston Ring Installation” on page 5.51).
3. Apply engine oil to ring compressor band and install band
(A) over piston rings.
4. Fully compress piston rings using compressor pliers (B) on
band.
Piston Ring Compressor Band, 87mm: PV-43570-3
Piston Ring Compressor Pliers: PV-43570-1
5. Apply tape to the sides of connecting rods to protect
cylinder from damage. Be sure to install piston with arrow
(C) pointing to MAG (water pump) end of crankshaft.
6. Align piston with bore and push into cylinder until all rings
are captive. Remove ring compressor.
CAUTION
Do not re-use circlips. Circlips become deformed
during the removal process.
Do not compress the new clip more than
necessary to prevent loss of radial tension.
Severe engine damage may result if circlips are
re-used or deformed during installation.
CAUTION
Be sure compressor band end gap does not align
with any ring end gap when compressing the rings.
C
A
B