Thoroughly clean all parts to assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
Assemble the piston and the connecting rod.
Use a hydraulic press for installation.
The piston front mark (A) and the connecting rod front mark (A) must face the timing chain side of the engine.
Pressing load : 500 ~ 1,500 kg (1,102 ~ 3,306 lb)
Assemble the piston rings.
Install the oil ring coil spring and two side rails by hand.
Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Position the piston rings so that the ring ends are as shown.
Assemble the connecting rod bearings.
Align the bearing (A) claw with the groove of the connecting rod and cap (B).
Install the bearings (A) in the connecting rod and cap (B).
Insert the piston and connecting rod assemblies into the cylinder bores.
Before installing the piston, apply a sufficient amount of engine oil to the ring grooves and cylinder bores.
Press the piston rings with a ring compressor and check that the rings are securely in place. Then insert the piston into the cylinder bore, and tap it in using the wooden handle of a hammer.
Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
Install the rod caps with bearings, and tighten the bolts.
Tightening torque :
17.7 ~ 21.8 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°
Do not reuse the connecting rod cap bolts.
Check the side clearance between piston and connecting rod.
Install the ladder frame.
Apply the liquid gasket on the ladder frame.
Bead width : 2.5 ~ 3.5 mm (0.0984 ~ 0.1378 in)
Apply the sealant, THREE-BOND 1217H or LOCTITE 5900H on the ladder frame rail portion and install it within five minutes. If sealant is applied to cylinder block bottom position, the sealant position should be the same as that of the ladder frame rail.
Apply sealant along the inner line of the bolt holes.
Install the ladder frame (A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Assemble the other parts in the reverse order of disassembly.
