Note: Lubricate the piston pin with clean engine oil.
- Install the connecting rod (3) and the piston pin (2) to the piston (1).
- Install the piston and connecting rod assembly to a bench vice. Use aluminium braces.
Warning: Observe extreme caution when removing circlips. Always wear adequate eye protection in order to avoid personal injury.
Warning: Use care when removing or installing the piston retainer ring. Ensure the EN-49941 remover/installer is installed properly onto the retainer ring and that hands and fingers are kept clear from the front of the tool. Otherwise, bodily injury may occur.
Note: Notch (2) on right side.
- Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (2).
- Push the piston pin retainer down with the thumb in the shown position (1) and hold.
Note: The EN-49941 installer should be applied in a perpendicular position to the piston pin retainer.
- Apply the EN-49941 installer (4) to the gudgeon pin retainer in the position shown (3) and push in direction of the arrow while pushing down with the thumb.
Note: Push the gudgeon pin retainer down in the position shown (2).
- Move the EN-49941 installer (1) carefully to the position shown while pushing in direction of the arrow until the gudgeon pin retainer engages in the gudgeon pin retainer groove.
- Push down the piston ring retainer to get a proper seat in the groove.
Note: Notch (4) on left side. EN-49941 installer should be used with left hand.
- Place the piston pin retainer in the piston pin retainer groove so that the ring gap lays on the notch (4).
- Push the gudgeon pin retainer down with the thumb in the position shown (1) and hold.
Note: The EN-49941 installer should be applied in a perpendicular position to the piston pin retainer.
- Apply the EN-49941 installer (3) to the gudgeon pin retainer in the position shown (2) and push in direction of the arrow while pushing down with the thumb.
Note: Push the gudgeon pin retainer down in the position shown (1).
- Move the EN-49941 installer (2) carefully to the position shown while pushing in direction of the arrow until the gudgeon pin retainer engages in the gudgeon pin retainer groove.
- Push down the piston ring retainer to get a proper seat in the groove.
- Remove the piston and connecting rod assembly from the bench vice.
- Install the piston rings. Use piston ring pliers (1).
Note: Mind the TOP marking on the piston rings.
- The piston rings must be ordered as follows:
| • | Upper compression ring (1) |
| • | Lower compression ring (2) |
| • | Piston oil ring with spacer (3), (4) |
- The piston ring joints must be positioned 90° to each other.
| • | Upper compression ring joint (2) |
| • | Lower compression ring joint (5) |
| • | Oil ring joint, upper part (1) |
| • | Oil ring joint, lower part (4) |
| • | Oil ring spacer joint (3) |
