Mark the connecting rod and piston properly to make sure that they will be reinstalled in the same cylinder from
which they were removed.
(1) Remove the connecting rod cap bolts (7, fig. 82) and the upper bearing shell (17).
(2) Using a piston ring spreading tool (1, fig. 84), spread the top compression ring (2) and remove it from the
(3) Remove the remaining two compression rings (9 and 10, fig. 82) and the oil ring (8) in the same manner as
the top compression ring (11).
(4) Remove the piston pin retaining rings (14) on both sides of the piston pin (13).
(5) Immerse the piston in a hot water (about 100° F.) and allow it to expand in order to facilitate removal of the
piston pin (13).
(6) Drive out the piston pin (13).
(7) Separate the connecting rod (16) from the piston (12).
d. Inspection. Wash all parts in cleaning solvent and blow them dry with clean compressed air. Remove the carbon
and foreign matter from the piston grooves. Inspect all parts thoroughly for cracks, chips, breaks, and mechanical defects.
Replace any defective parts.
e. Piston Pin Fitting.
(1) This engine has aluminum-alloy pistons. The pistons have been fitted with pins that cannot be pushed in by
hand until the piston has been heated.
(2) Replace the pistons if the pins are loose in the pistons or the piston boss is out-of-round.
(3) The standard finished size of the piston pin is 0.8592 to 0.8593 inch. The pins are manufactured with an
out-of-round and taper allowance of only 0.0002 inch. The proper piston pin fit is 0.0003 inch loose in the
piston pin bushing and 0.0003 inch tight in the piston pin boss.
(4) When installing the piston pin, heat the piston in hot water (about 100° F). Install the pin (2, fig. 85) in the
piston boss and drive it into the piston (3) and connecting rod bushing with a plastic hammer (1).
f. Piston Ring Gap.
(1) The correct piston-ring-gap clearance for this engine is 0.017 to 0.007 for both compression and oil rings.
(2) Install the piston ring in the cylinder sleeve and slide the piston into the sleeve above the piston ring.
(3) Push the piston up against the piston ring until the piston ring is square with the cylinder bore.