Piston and Connecting Rod Assembly - If Removed

1. Reassemble the Piston and Connecting Rod by sliding the Piston Pin back into place in the Piston. If necessary use the wooden dowel and mallet to tap the Piston Pin back into place. Ensure the letters that were previously marked on the Connecting Rod are matched and aligned with the letters on the bottom side of the Piston as shown.

   

   

2. Replace the Piston Spring Clip into the piston as shown, use the needle nose pliers for this operation.

   

   

3. Please ask the instructor for help at this point, as the ENGR 100 Ring Compressor is different.  To insert the Piston and Connecting Rod Assembly back into the Cylinder Block it will be necessary to use the piston ring compressor. Adjust the piston ring compressor to a slightly larger diameter than the Piston and Compression Rings. To do this, hold the spring lever down, while turning the adjustment lever counter-clockwise, when the desired size is reached release the spring lever. Be sure to lubricate the compression and the cylinder bore with a small amount of engine oil before attempting to push the piston into the cylinder.
4. Remove the Cylinder Head Gasket if it has not already been removed.
5. Place the piston ring compressor flat onto the Cylinder Block, then slide the Piston and Connecting Rod assembly through the tool. Allow the Piston to rest on the Cylinder Block, then tighten the piston ring compressor by turning the lever in a clockwise direction until it is snug around all sides of the piston. The Piston Compression Rings should now be fully compressed. DO NOT drive the piston down into the cylinder bore with the mallet. The goal is to gently push it down while not allowing the big end of the connecting rod to strike the crank journal.

   

   

6. Turn the piston ring compressor and Piston until the big end of the Connecting Rod is properly aligned with the Crankshaft. This will prevent damaging or jamming the Connecting Rod when the piston is pushed inside the Cylinder Block.
7. Using the end of the mallet push the Piston through the piston ring compressor and into the Cylinder Block as shown.
8. Once the Piston has been put into the Cylinder Block, the big end of the Connecting Rod must be brought into position around the throw of the Crankshaft. Reattach the other half of the big end of the Connecting Rod using the correct bolts and the 5/16" socket and the ratchet. Be sure that the ratchet has been switched into tighten mode and that the bolts are tightened in a clockwise direction. Using the torque wrench and the 5/16" socket tighten the bolts to 100 in-lbs, or 8.3 ft-lbs. If you do not know how to use a torque wrench ask for assistance. Do not forget to attach the Oil-Mixing arm to the big end of the Connecting Rod, ensuring that it does not interfere with the motion of the Crankshaft.