Assembly

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





2. Heat piston to 60 - 70° C (140 - 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 positions.
- When replacing piston rings, these without punchmarks, present, piston rings can be mounted with either side up.





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





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





2. A plastic-zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown in the figure.
- d2: Select minimum diameter in the measuring area.
- If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones. The limit (d1 - d2) is 0.11 mm (0.0043 inch)





3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as follows:





NOTE: Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.

- Lubricate threads and seat surfaces of the bolts with new engine oil.
- Tighten all bolts to 32 - 38 Nm (24 - 28 ft. lbs.).
- Turn all bolts 90 - 95° clockwise with an angle wrench.
^ After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

4. Measure crankshaft end play. The standard end play is 0.10 - 0.25 mm (0.0039 - 0.0098 inch) and the limit is 0.30 mm (0.0118 inch). If beyond the limit, replace bearing with a new one.
5. Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used.





6. Install pistons with connecting rods into the corresponding cylinders with ring compressor tool No. EM03470000, or equivalent.

NOTE:
- Be careful not to scratch cylinder wall with the connecting rod.
- Arrange so that front mark on piston head faces toward engine front.
- A plastic zone tightening method is used for tightening connecting rod bolts and nuts. Check the old bolts for deformation before re-using them.





- Ensure that the connecting rod nut can be screwed smoothly as far as the bolt thread end. If this is not possible, use slide calipers to measure the outside diameter of the narrowest thread part of the bolt at 16 mm (0.63 inch) from the thread end. Replace the connecting rod bolt and nut, if under the limit.
- The standard value is 7.90 - 8.00 mm (0.3110 - 0.3150 inch) and the limit is 7.75 mm (0.3051 inch).
- Install connecting rod caps.





- Lubricate threads and seat surfaces with new engine oil. Tighten connecting rod bearing cap nuts to 19 - 21 Nm (14 - 15 ft. lbs.). Then turn the nuts 90 - 95° clockwise with an angle wrench.





7. Measure connecting rod side clearance. The standard value is 0.20 - 0.35 mm (0.0079 - 0.0138 inch) and the limit is 0.40 mm (0.0157 inch). If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.