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 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. Install signal plate to crankshaft using dowel pin to properly position the signal plate. Remove the dowel pin after the signal plate bolts are tightened. Tighten the signal plate bolts.

Signal plate bolts: ...............7.64 - 9.22 Nm (0.78 - 0.94 kg-m, 67.7 - 81.6 inch lbs.)

Dowel pin diameter: ...................6 mm (0.24 inch)










2. 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.
- Apply new engine oil to bearing surfaces.







3. Install crankshaft and main bearing caps and tighten bolts to the specified torque:
46.1 - 52.0 nm (4.78 - 5.30 kg-m, 34.0 - 38.8 ft-lb)
- 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 in figure.
- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.







4. Measure crankshaft free end play.

Crankshaft free end play
Standard .................0.060 - 0.220 mm (0.0024 - 0.0087 inch)
Limit ......................0.3 mm (0.012 inch)

If beyond the limit, replace thrust bearing with new ones.







5. 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.







6. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
- 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.







b. Install connecting rod caps. Apply new engine oil to bolt threads and nut seating surfaces. Tighten connecting rod cap nuts in two stages:

Stage 1: ....................13.72- 15.68 Nm (1.399- 1.599 kg-m, 10.120 - 11.566 ft. lbs.)
Stage 2: ............................15 - 40 degrees clockwise, or 23 - 28 Nm (2.3 - 2.9 kg-m,17 - 21 ft. lbs.)







7. Measure connecting rod side clearance.

Connecting rod side clearance
Standard: .....................0.200 - 0.470 mm (0.0079 - 0.0185 inch)
Limit: ........................0.52 mm (0.0205 inch)

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







8. Install rear oil seal retainer.
a. Before installing rear oil seal retainer, remove old Silicone RTV Sealant from cylinder block and retainer.
b. Apply a continuous bead of Silicone RTV Sealant to rear oil seal retainer.
- Use Genuine Silicone RTV Sealant, or equivalent.
- Apply around inner side of bolt holes.

9. Install crankshaft position sensor (POS).

Crankshaft position sensor bolt: ........................7.2 - 10.8 Nm (0.73 - 1.10 kg-m, 63.4 - 95.5 inch lbs.)







10. Install knock sensor at correct angle.

Knock sensor bolt: 15.7 - 20.6 Nm (1.6 - 2.1 kg-m, 12 - 15 ft. lbs.)