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 replaced, make sure that piston rings are mounted in their original positions.
- Install new piston rings either side up if there is no punch-mark.
- Align piston rings so that end gaps are positioned as shown in the image.

CRANKSHAFT





1. Set main bearings in their proper positions on cylinder block and main bearing beam.
- Confirm that correct main bearings are used. Refer to "Inspection" of this section.
- Apply engine oil to bearing surfaces.

Main Cap Torque Sequence:

2. Install crankshaft and main bearing cap and tighten bolts to the specified torque.
- Lubricate threads and seat surfaces of the bolts with new engine oil.
- Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting 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: 0.05 - 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. Refer to "Inspection".
- Install bearings so that oil hole in connecting rod aligns with oil hole of bearing.
- Apply engine oil to bolt threads and bearing surfaces.








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

b. Install connecting rod bearing caps.
- Lubricate threads and seat surfaces with new engine oil.
- Tighten connecting rod bearing cap nuts to the specified torque.

Connecting rod bearing nut:
1. Tighten to 14 to 16 Nm (1.4 to 1.6 kg-m, 10 to 12 ft. lbs).
2. Tighten bolts 60 +5/-0 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten them to 38 to 44 Nm (3.9 to 4.5 kg-m, 28 to 33 ft. lbs).





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).