Assembly
PISTON1. Install a new snap ring on one side of piston pin hole.
2. Heat the piston to 60° - 70°C (140° - 158°F) and assemble the piston, piston pin, connecting rod and the new snap ring on the other side.
^ Align the direction of the piston and connecting rod with the marks as shown.
^ Numbers stamped on the connecting rod and cap correspond to each cylinder, and should be aligned when assembled as shown.
^ After assembly, check that the connecting rod swings smoothly on the piston.
3. Install and align the piston rings at 90° degree angles as shown.
CRANKSHAFT
1. Set the main bearings in their proper positions on the cylinder block and main bearing caps.
^ Confirm that the correct main bearings are used.
^ Apply new engine oil to the bearing friction surfaces
2. Install the crankshaft and main bearing caps and tighten the bolts to the specified torque in numerical order as shown.
^ Prior to tightening the bearing cap bolts, place the bearing cap in the proper position by shifting the crankshaft in the axial direction.
^ Tighten the bearing cap bolts gradually in two or three steps. Tighten the bearing cap bolts in numerical order as shown.
^ After securing the bearing cap bolts, check that the crankshaft turns smoothly by hand.
^ Lubricate the threads and seat surfaces of the bolts with new engine oil.
3. Measure the crankshaft end play as shown.
Crankshaft end play
Standard: 0.050 - 0.170 mm (0.0020 - 0.0067 inch)
Limit: 0.30 mm (0.0118 inch)
If beyond the limit, replace the bearing with a new one.
4. Install the connecting rod bearings in the connecting rods and connecting rod caps.
^ Confirm that the correct sized bearings are installed.
^ Install the bearings so that the oil hole in the connecting rod aligns with the oil hole in the bearing as shown.
5. Install the pistons with connecting rods using Tool as shown.
a. Install the piston assemblies into their corresponding cylinder bores using Tool as shown.
^ Do not scratch the cylinder wall with the connecting rod.
^ Position the piston so the front mark on the piston head faces toward the front of the engine.
b. Install the connecting rod bearing caps and nuts.
^ Lubricate the connecting rod bearing cap stud threads and nut seats with new engine oil.
^ Tighten the connecting rod bearing cap nuts to specification in two steps. Only if an angle wrench is not available, tighten the connecting rod bearing cap nuts to the torque specification in step 2.
Connecting rod bearing cap nut
Step 1: 14 - 16 Nm (1.4 - 1.6 kg-m, 10 - 12ft. lbs.).
Step 2: 60° - 65° degrees clockwise, or 38 - 44 Nm (3.9 - 4.5 kg-m, 28 - 33 ft. lbs.).
6. Measure the 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 the connecting rod and/or crankshaft.
7. Install the rear oil seal and retainer.
REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)
1. Remove the pilot bushing (M/T) or pilot converter (A/T) using Tool as shown.
2. Install the pilot bushing (M/T) or pilot converter (A/T) as shown.