Reassembly

Reassembly






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.
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. 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.






2. Install crankshaft and main bearing caps, then tighten bolts to the specified torque.
Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap.
Apply new engine oil to threads and seating surfaces of bearing cap bolts before installing them.

Tightening Procedure:
a. Tighten all bolts to 7 to 12 Nm (0.7 to 1.3 kg-m, 61 to 112 ft. lbs.).






b. Turn all bolts 70 to 80 degrees clockwise with Tool or suitable angle wrench.
c. Loosen all bolts completely.
d. Tighten all bolts to 33 to 38 Nm (3.3 to 3.9 kg-m, 24 to 28 ft. lbs.).
e. Turn all bolts 30 to 35 degrees clockwise with Tool or suitable angle wrench.






If an angle wrench is not available, mark all bearing cap bolts on the side facing engine rear. Then, turn each bolt specified degrees clockwise. Confirm angle of degrees with a graduator, not by eye measurement.
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 thrust bearing with 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.
Apply new engine oil to bolt threads and bearing surfaces.

5. 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 scratch crankshaft pin journals.
Arrange so that front mark on piston head faces engine front.
Apply new engine oil to piston rings and sliding surface of piston.






b. Install connecting rod caps.
Apply new engine oil to threads and seat surfaces. Tighten connecting rod cap nuts using the following procedure:

a. Tighten nuts to 13.7 to 15.7 Nm (1.4 to 1.6 kg-m, 10 to 12 ft. lbs.).
b. Turn all nuts 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten nuts 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 ...........0.20 - 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.

7. Install rear oil seal retainer.






a. Before installing rear oil seal retainer, remove old liquid gasket from mating surface.
Also remove old liquid gasket from mating surface of cylinder block.






b. Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer.
Use Genuine RTV silicone sealant part No. 999MP-A7007 or equivalent.
Apply around inner side of bolt holes.