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 in image.

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





- 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 used.
- Apply new engine oil to bearing surfaces.

Torque Sequence:

2. Install crankshaft and main bearing cap and tighten bolts to the specified torque.
- Apply new engine oil to bolt threads and seat surfaces.
- Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap.
- Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown in image.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.





3. Measure crankshaft end play.

Crankshaft end play:
Standard: 0.05 - 0.18 mm (0.0020 - 0.0071 inch)
Limit: 0.3 mm (0.012 inch)

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.
- Apply new engine oil to bearing surfaces, bolt threads and seating surfaces.





5. Install pistons with connecting rods
a. Install them into corresponding cylinders with Tool.
- Be careful not to scratch cylinder wall with connecting rod.
- Arrange so that front mark on piston head faces toward engine front.
- Be careful not to scratch crankshaft journals with connecting rod bolts.
- Apply new engine oil to piston rings and sliding surface of piston.





b. Install connecting rod bearing caps.
- Apply new engine oil to threads and seat surfaces.
- Tighten connecting rod bearing cap nuts in the following procedure:

1. Tighten to 14 to 16 Nm (1.4 to 1.6 kg-m, 10 to 12 ft. lbs.).
2. Turn all nuts 60 to 65 degrees clockwise. If an angle wrench is not available, mark all connecting rod bearing cap nuts on the side facing engine front. Then, turn each nut 60 to 65 degrees clockwise.





6. Measure connecting rod side clearance. Connecting rod side clearance:

Standard: 0.2 - 0.4 mm (0.008 - 0.016 inch)
Limit: 0.6 mm (0.024 inch)

If beyond the limit, replace connecting rod and/or crankshaft.

REPLACING PILOT BUSHING





1. Remove pilot bushing (M/T) or pilot converter (A/T).





2. Install pilot bushing (M/T) or pilot converter (A/T).