Assembly

Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.






2. Heat piston to 60 to 70°C (140 to 1 58°F) and assemble piston, piston pin, connecting rod and new snap ring.
- Align the direction of piston and connecting rod.
- Numbers stamped on connecting rod and cap correspond to each cylinder.
- After assembly, make sure connecting rod swings smoothly.






3. Set piston rings as shown.

CAUTION:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.






4. Set piston rings as shown.







CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and main bearing cap.
- Confirm that correct main bearings are used.






2. Install crankshaft and main bearing caps and tighten bolts to the specified torque.
- Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction.
- Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially.
- After. securing bearing cap bolts, make sure crankshaft turns smoothly by hand.






3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.050 - 0.170 mm (0.0020 - 0.0067 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace bearing with a new one.






4. Install connecting rod bearings in connecting rods and connecting rod caps.
- Confirm that correct bearings are used
- Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.






5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
- Be careful not to scratch cylinder wall by connecting rod.
- Arrange so that front mark on piston head faces toward front of engine.






b. Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts to the specified torque.
Connecting rod bearing nut
(1) Tighten to 14 to 16 N.m (1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2)Turn nuts 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten nuts to 38 to 44 N.m (3.9 to 4.5 kg-m, 28 to 33 ft-lb).






6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20- 0.35 mm (0.0079-0.0138 in)
Limit
0.40 mm (0.0157 in)
If beyond the limit, replace connecting rod and/or crankshaft.