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.





CAUTION:
- When piston rings are not replaced, make sure that piston rings are mounted in their original positions.
- When replacing piston rings, these without punch-marks, 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. Instructions for re-use of main bearing cap bolts.
- A plastic zone tightening method is used for tightening 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.

Limit (d1 - d2): 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.
- Tightening procedure
1. Tighten all bolts to 32 to 38 Nm (3.3 to 3.9 kg-m, 24 to 28 ft. lbs.).
2. Turn all bolts 90 to 95 degrees clockwise with angle wrench.
- Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
- Lubricate threads and seat surfaces of the bolts with new engine oil.
4. Measure crankshaft end play.

Crankshaft end play:
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit: 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.
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.





b. 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.

Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 inch)
Limit: 7.75 mm (0.3051 inch)





c. Install connecting rod 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 nuts to 19 to 21 Nm (1.9 to 2.1 kg-m, 14 to 15 ft. lbs.).
2. Turn nuts 90 to 95 degrees clockwise with angle wrench.





7. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit: 0.40 mm (0.0157 inch)

If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.