Disassembly and assembly

82 KENR6226-01
Disassembly and Assembly Section
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. If the connecting rod caps were temporarily
installed, remove the connecting rod caps. If
necessary, thoroughly clean all of the components.
2. Apply clean engine oil to the cylinder bore, to the
piston rings, to the outer surface of the piston and
to the connecting rod bearings.
Note: Install the connecting rod bearings dry
when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil to the connecting rod
bearings during final assembly.
3. Rotate the crankshaft until the crankshaft pin
is at the bottom center position. Lubricate the
crankshaft pin with clean engine oil.
g01311916
Illustrat
ion 154
Typical example
g013119
24
Illustration 155
Typical example
4. Ensure that the gaps for the piston rings are at
120 degrees awa
y from each other. Install Tooling
(A) onto piston (5). Use tape or rubber tubing on
the connecting rod bolts to protect the crankshaft
journals.
Note: Ensure that Tooling (A) is installed correctly
and that the p
iston can easily slide from the tool.
Ensure that the piston and the connecting rod
assembly are installed in the correct cylinder. Align
number (X) on
thesideoftheconnectingrodtothe
right side of the cylinder block. The right hand side is
determined from the flywheel end of the engine.
5. Carefully push the piston and the connecting rod
assembly into the cylinder bore and onto the
crankshaft
pin.
Note: Do not damage the finished surface of the
crankshaft
pin.
6. Install connecting rod cap (2) onto connecting rod
(4). Ensur
e that number (X) on the connecting rod
cap matches number (X) on the connecting rod.
Install nuts (1).
For 402D-05 and 403D-07 engines, tighten nuts
(1) to a torque of 23 N·m (16 lb ft).
For 403D-11 and 404D-15 engines, tighten nuts
(1) to a torque of 32 N·m (24 lb ft).
For 403D-15, 403D-15T, 403D-17, 404D-22,
404D-22T and 404D-22TA engines, tighten nuts
(1) to a tor
queof52N·m(38lbft).
7. Repeat Steps 1 through 6 for the remaining
pistons a
nd connecting rods.
8. Ensure that the installed connecting rod assembly
has tacti
le side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
End By:
a. Install the suction pipe. Refer to Disassembly and
Assembly
, “Engine Oil Pump - Install”.
b. Install the cylinder head. Refer to Disassembly
and Assem
bly, “Cylinder Head - Install”.
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