Assembly

PISTON





1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70° C (140 to 1 58° 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 image.

CRANKSHAFT





1. Set main bearings in their proper positions on cylinder block and main bearing cap.
- Confirm that correct main bearings are used.
- Apply engine oil to bearing surface.








2. Install crankshaft, main bearing caps and beam 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.

- Tightening procedure
1. Tighten bolts [(1) - (20)] to (a).
2. Turn bolts [(1) - (20)] (b) degrees clockwise with angle wrench.
3. Tighten all bolts [(21) - (30)] to (c).

- After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.





3. Measure crankshaft end play

Crankshaft end play:
Standard: 0.10 - 0.26 mm (0.0039 - 0.0102 inch)
Limit: 0.30 mm (0.0118 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.








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 front of engine.
- Apply engine oil to piston rings and sliding surface of piston.

b. Install connecting rod caps
- Apply engine oil to bolt threads and bearing surface. Tighten connecting rod bearing cap nuts to the specified torque.

Tightening procedure:
1. Tighten nuts to 14 to 16 Nm (1.4 to 1.6 kg-m, 10 to 12 ft. lbs.).
2. Turn nuts 60 to 65 degrees clockwise with angle wrench.





6. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard: 0.20 - 0.35 mm (0.0079 - 0.013 inch)
Limit: 0.40 mm (0.0157 inch)

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

7. Install rear oil seal retainer.

REPLACING PILOT CONVERTER





1. Remove pilot converter.
2. Install pilot converter.