11. Assembly of Piston and Connecting Rod Assemblies

- Tools Required
- SA9lOlE Piston Pin Retainer/Replacer





1. Assemble piston and connecting rod:
a. Align the mark on top of the piston with the front of the engine. Assemble the connecting rod to the piston with the bearing tang slots directed toward the exhaust manifold side.

IMPORTANT: It is standard practice to assemble the piston and connecting rod with bearing tang slots in the rod directed toward the exhaust manifold side.

NOTICE: Carefully remove any burrs in the piston pin bore, next to the snap ring groove, using an X-ACTO knife. This will prevent piston pin scoring during installation.





b. Coat the piston pin with engine oil.
c. Install the piston pin using service tool SA9lOlE.





d. Check that the piston and connecting rod moves smoothly back and forth on the piston pin.





e. Install the retainer in the service tool's (SA9lOlE) cone with the ring's open ends directed away from the tools slotted opening. Set the cone on it's base and push the snap ring down through the cone until seated with the driver.

IMPORTANT: Snap ring cone SA 9101E-2 must be used with 2000 model year pistons. This is the snap ring cone used in 1994 and earlier years.

f. Lay the piston on a clean block of wood. Position the cone with snap ring and driver over the piston pin hole with the cone's slotted opening facing toward the top of the piston. Firmly push the driver downward until the retainer is seated in the snap ring groove.





2. Install the piston rings:
a. Install the oil ring expander and two side rails by hand.





b. Using a piston ring expander, install the two compression rings.

IMPORTANT: The top ring is thinner than the second ring. The top ring is symmetrical and can be installed with either side up. The second ring has a pip mark which must be installed with the pip mark up.





NOTICE: Do not align the ring gaps. Each ring should be rotated 90 to 120 degrees from each other around the piston.





3. Install bearings:
Install the upper bearing in the connecting rod. Apply a small amount of oil to the bearing surfaces and piston rings.