Aluminum Piston
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| Illustration 1 | g01156566 |
Aluminum piston | |
Note: Assemble the rod and aluminum pistons with the marking "front" on the piston body in the opposite direction of the part number on the rod assembly. Install the rod and piston group in the engine with the part number on the rod assembly to the rear of the engine. The rear of the engine is the flywheel end of the engine. Lubricate the rod and piston group with clean engine oil before you insert the rod and piston group into the block.
(1) Piston body assembly
Lubricate the entire piston in zone (A) prior to assembly into the cylinder block. Use clean engine oil.
Piston Rings
Top Ring and Intermediate Ring
(2) The top ring has the mark "UP-1".
Install the piston ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to the right of the ring end gap.
The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.
Cylinder bore size ... 110.025 mm (4.3317 inch)
Clearance ... 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
The piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore.
Increase ... 0.09 mm (0.004 inch)
(3) The intermediate ring has the mark "UP-2".
Install the piston ring with the side marked "UP-2" toward the top of the piston. The colored stripe faces to the right of the piston ring end gap.
Thickness of the new piston ring ... 2.98 ± 0.01 mm (0.1173 ± 0.0004 inch)
The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.
Cylinder bore size ... 110.025 mm (4.3317 inch)
Clearance ... 1.200 ± 0.125 mm (0.0472 ± 0.0049 inch)
The intermediate piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore.
Increase ... 0.09 mm (0.004 inch)
Oil Control Ring
(4) The oil control piston ring has a spring that is installed with the ring. The gap in the spring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The light green colored portion of the spring must be visible at the ring end gap.
Thickness of the new piston ring ... 3.985 ± 0.010 mm (0.1569 ± 0.0004 inch)
The ends of the oil control piston ring have a clearance when the ring is installed in a cylinder with a specific bore size.
Cylinder bore size ... 110.025 mm (4.3317 inch)
Clearance ... 0.45 ± 0.15 mm (0.018 ± 0.006 inch)
The oil control piston ring has an increase in clearance for each 0.03 mm (0.001 inch) increase in the cylinder liner bore.
Increase ... 0.09 mm (0.004 inch)
After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.
Piston Pin Bore
(5) Steel piston pin diameter ... 39.988 ± 0.005 mm (1.5743 ± 0.0002 inch)
(5) Aluminum piston pin diameter ... 39.993 ± 0.005 mm (1.5745 ± 0.0002 inch)
Internal diameter of the piston pin for steel pistons ... 18 ± 0.5 mm (0.709 ± 0.0197 inch)
Internal diameter of the piston pin for aluminum ... 23 ± 0.5 mm (0.906 ± 0.0197 inch)
Length of piston pin for steel pistons ... 74.5 ± 0.15 mm (2.933 ± 0.006 inch)
Length of piston pin for aluminum pistons ... 89.95 ± 0.15 mm (3.541 ± 0.006 inch)
Thoroughly lubricate the piston pin with clean engine oil prior to assembly.
(6) Connecting Rod