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Piston & Rod Assembly

  1. Remove cylinder head. See CYLINDER HEAD  under REMOVAL & INSTALLATION. Remove oil dipstick guide, oil pan and screen. See OIL PAN  under REMOVAL & INSTALLATION.
  2. Ensure pistons, connecting rods and rod caps are marked for reassembly. Remove carbon from top of cylinder bores. Remove connecting rod caps. Install protective hose over connecting rod bolts.
  3. Remove connecting rod and piston assembly through top of cylinder block. Mark cylinder number on piston crown. Remove piston rings.
  4. Remove circlips and push piston pin out by hand. Check piston pin-to-bore fit. Pin should press in piston smoothly by hand at room temperature. When assembling, apply engine oil to outside of pin and to piston pin bore.
  5. Position piston upward. Install circlip in pin bore. Align piston to rod, with arrow on top of piston and "86F" mark on connecting rod on the same side. Insert piston pin and insert remaining circlip. Position circlips with opening horizontal to piston top and facing oil hole in connecting rod.
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