Assembly

PISTON
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70° C (140 to 158° 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.

NOTE:
- When piston rings are not replaced, make sure that piston rings are mounted in their original position.
- Install new piston rings either side up if there is no punch mark.





- Align piston rings so that end gaps are positioned as shown.





CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block and main bearing cap.
- Confirm that correct main bearings are selected by using Method A or Method B. Refer to Crankshaft Main Bearing / Testing and Inspection / Procedures.
Testing and Inspection
- Apply new engine oil to bearing surfaces.





2. Install crankshaft and main bearing caps and tighten bolts to 46.1 - 52.0 mm (34.00 - 38.36 ft. lbs.).
- Apply new engine oil to the bolt thread and seat surface.
- Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing caps.





- Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.





3. Measure crankshaft end play. The standard crankshaft end play is 0.060 - 0.180 mm (0.0024 - 0.0071 inch). The limit is 0.3 mm (0.012 inch). If beyond the limit, replace thrust bearings with new ones.
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.
- Apply new engine oil to bolt threads and bearing surfaces.





5. Install pistons with connecting rods into their corresponding cylinders with piston ring compressor tool No. EM03470000, or equivalent
- Make sure connecting rod does not scratch cylinder wall.
- Make sure connecting rod bolts do not scratch crankshaft pin journals.
- Arrange so that front mark on piston head faces engine.
- Apply new engine oil to piston rings and sliding surface of piston.
- Apply new engine oil to bolt threads and nut seating surfaces and torque connecting rod caps as follows:
1. Tighten to 13.72 to 15.68 Nm (10.120 - 11.566 ft. lbs.).





2. Turn nuts to 35 to 40° clockwise with an angle wrench. If an angle wrench is not available, tighten nuts to 23 to 28 Nm (17 to 21 ft. lbs.).





6. Measure connecting rod side clearance. The standard connecting rod side clearance is 0.200 - 0.470 mm (0.0079 - 0.0185 inch). The limit is 0.50 mm (0.0197 inch). If beyond the limit, replace connecting rod and/or crankshaft.





7. Remove old liquid gasket from cylinder block and retainer and apply a continuous bead of liquid gasket to rear oil seal retainer and install rear oil seal retainer.
- Use Genuine Liquid Gasket, or equivalent.
- Apply around inner side of bolt holes.