Power Solutions International — Steps to assemble piston-rod group
Repair & overhaul
From a Power Solutions International service manual — check it applies to your exact model before use.
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Before you start
- Do not reuse the bolts
- Numbered pistons should not be mixed
Procedure
- Install one circlip into piston circlip groove, corner angle inward, opening upward
- Insert connecting rod small end into piston, install piston pin, install other circlip
- Install oil ring, second compression ring and first compression ring with piston ring plier, TOP mark upward
- Clean cylinder inner wall, crankshaft lever and piston-rod assembly; apply clean oil on motion pairs
- Set ring openings: first ring 30° to pin center line, second 120° to first, oil ring 120° to both
- Rotate flywheel until cylinders 1 and 6 reach BDC; install thrust plates of cylinders 1 and 6
- Screw on connecting rod bolts; rod parting surface faces left side of cylinder block
- Tighten connecting rod bolts to 30Nm in symmetry, then turn 60°±4°
- For M10x1 bolts, tighten to 30Nm and turn 120°±5°
- Do not reuse the bolts
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Connecting rod bolts 30Nm then 60°±4°
- M10x1 bolts 30Nm then 120°±5°
Source: Power Solutions International service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.