Note: KZ series engine pistons are different. Make no mistake with the choice during installation.
1. Assemble the connecting rod and piston group.
A) Apply some engine oil to the piston pin and into the piston boss bore. Align marks "before" piston and connecting rod.
b) Install the piston pin in the special tool.
V) Press in the piston pin with a hydraulic press.
V) Make sure the piston turns freely on the piston pin.
2. Install piston rings.
A) Install the expander and two oil ring scrapers.
b) Use a piston ring expander to install two compression rings; and ring marks ("T" or "R") should be facing up as shown.
V) Install the piston rings in the grooves so that their locks are located as shown in the figure.
Note: do not match the locks of the rings.
KZ series.
1 - expander lock,
2 - compression ring lock No. 1,
3 - lock of the upper scraper of the oil scraper ring,
4 - compression ring lock No. 2,
5 - lock of the lower scraper of the oil scraper ring.
Pistons of KZ series engines.
EJ series.
1 - compression ring lock No. 2,
2 - lock of the lower scraper of the oil scraper ring,
3 - lock of the oil scraper ring expander,
4 - compression ring lock No. 1,
5 - lock of the lower scraper of the oil scraper ring.
3. Install the connecting rod bearing shells.
A) Align the lug of the bushing with the recess in the lower head of the connecting rod and with its cover.
b) Insert the bushings into the bottom end of the connecting rod and into the connecting rod cap.