Assembly

Components





Canada Models-Block Heater

PISTON
1. Install 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 new snap ring.
^ Align the direction of the piston and connecting rod.
^ Numbers stamped on the connecting rod and cap correspond to each cylinder.
^ After assembly, make sure the connecting rod swings smoothly.





3. Set piston rings positioning the gaps at 90� degree angles as shown.

CRANKSHAFT





1. Set the main bearings in their proper positions on the cylinder block journals and main bearing caps.
^ Confirm that the correct main bearings are installed.
^ Apply new engine oil to the bearing surfaces.

Main Bearing Cap Assembly Sequence:

2. Install the crankshaft and main bearing caps and tighten the bolts in numerical order as shown, gradually in two or three steps, to specification.
^ Prior to tightening the main bearing cap bolts, place the main bearing cap in the proper position by shifting the crankshaft in the axial direction.
^ Tighten the main bearing cap bolts gradually in two or three steps to specification in numerical order as shown.
Main bearing cap bolts : 90 - 100 Nm (9.2 - 10.2 kg-lb, 57 - 74 ft. lbs.)
^ After tightening the main bearing cap bolts, check that the crankshaft turns smoothly by hand.
^ Lubricate the threads and seat surfaces of the main bearing cap bolts with new engine oil.





3. Measure the crankshaft end play using a dial gauge 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 bearing with a new one.





4. Install the connecting rod bearings in the connecting rods and connecting rod caps.
^ Check that the correct connecting rod bearings are being installed.
^ Install the connecting rod bearings so the oil hole in the connecting rod aligns with the oil hole in the bearing.
5. Install the pistons with connecting rods.





a. Install the piston assemblies into their corresponding cylinders using Tool.
^ 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.
^ Lubricate the connecting rod bearing cap stud threads and nut seats with new engine oil.
^ Tighten the connecting rod bearing cap nuts in two steps to the specification. Only if an angle wrench is not available, tighten the connecting rod bearing cap nuts to specification in step 2.
Connecting rod bearing cap nut
Step 1 : 14 to 16 Nm (1.4 to 1.6 kgf-cm, 10 to 12 ft. lbs.).
Step 2 : 60° - 65° degrees clockwise, or 38 - 44 Nm (3.9 - 4.5 kgf-cm, 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 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) using Tool as shown.