FE02-0235b

10. Check  whether  the  engine  block  cylinder  bore  is  worn,

runout and taper.

11. Check whether the engine block cylinder bore is polished,

if necessary, slightly polish the cylinder bore.

12. With a ruler and gap regulator, check the engine block top

surface flatness.

Standard Value: 0.05 mm (Metric) 0.002 in (US English)

FE02-0236b

13. Select a new set of piston rings, use a gap regulator to

measure piston ring end gap.

Oil Ring End Gap:
0.20-0.70 mm (Metric) 0.0079-0.0276 in (US English)

Second Compression Ring End Gap:
0.40-0.55 mm (Metric) 0.0157-0.0217 in (US English)

First Compression Ring End Gap:
0.25-0.35 mm (Metric) 0.0098-0.0138 in (US English)

14. Check the connecting rod bearings gap.

Standard Value:
0.020-0.044 mm (Metric) 0.0007-0.0017 in (US English)

15. check the connecting rod bearing clearance.

Standard Value:
0.16-0.342 mm (Metric) 0.006-0.0135 in (US English)

Installation Procedure:

First Ring
Upper Ring

Engine Front

Second Ring

Lower Ring

FE02-0237b

1.

install piston rings.

Note

Note when installing the piston rings do not expand
too much, otherwise it will break piston rings.

2.

Install  the  piston  rings  to  the  location  as  shown  in  the
graphic.

Note

Oil ring opening can not be parallel to the piston pin
axis.

Engine

Engine Mechanical System JL4G18-D

2-403

FE02-0238b

3.

With the new engine oil lubricate the cylinder wall.

4.

With the new engine oil lubricate the piston, use universal
tools and wood handle to install cylinder No.1 piston rod
components marked with cylinder No.1 location.

Note

The dot mark on the piston top surface should face
the engine front end. Note that during the installation
process prevent the lower connecting rod hitting the
crankshaft journal, causing damage.

FE02-0239b

5.

Install  the  cylinder  No.1  connecting  rod  bearing  cap
marked with cylinder No.1 location.

Note

The  dot  mark  on  the  bearing  cap  should  face  the
engine front end.

FE02-0240b

6.

Install and tighten cylinder No.1 connecting rod bearing
cap bolts.

Torque
First Pass: 20 Nm (Metric) 14.8 lb-ft (US English)
Second Pass: 51 Nm (Metric) 37.8 lb-ft (US English)

2-404

Engine Mechanical System JL4G18-D

Engine

FE02-0241b

7.

With a small amount of new engine oil lubricate the piston,
use universal tools and a wood handle to install cylinder
No.4 piston rod components marked with cylinder No.4
location.

Note

The dot mark on the piston top surface should face
the engine front end. Note that during the installation
process prevent the lower connecting rod hitting the
crankshaft journal, causing damage.

FE02-0242b

8.

Install  the  cylinder  No.4  connecting  rod  bearing  cap
marked with cylinder No.4 location.

Note

The  dot  mark  on  the  bearing  cap  should  face  the
engine front end.

FE02-0243b

9.

Install and tighten cylinder No.1 connecting rod bearing
cap bolts.

Torque
First Pass: 20 Nm (Metric) 14.8 lb-ft (US English)
Second Pass: 51 Nm (Metric) 37.8 lb-ft (US English)

Engine

Engine Mechanical System JL4G18-D

2-405

FE02-0244b

10. Rotate the crankshaft 180 °, so that cylinder No.2 and 3

are at BDC positions. With the new engine oil lubricate the
piston, use universal tools and a wood handle to install
cylinder No.2 piston connecting rod component marked
with cylinder No.2 location.

Note

The dot mark on the piston top surface should face
the engine front end. Note that during the installation
process prevent the lower connecting rod hitting the
crankshaft journal, causing damage.

FE02-0245b

11. Install  the  cylinder  No.2  connecting  rod  bearing  cap

marked with cylinder No.2 location.

Note

The  dot  mark  on  the  bearing  cap  should  face  the
engine front end.

FE02-0246b

12. Install and tighten cylinder No.2 connecting rod bearing

cap bolts.

Torque
First Pass: 20 Nm (Metric) 14.8 lb-ft (US English)
Second Pass: 51 Nm (Metric) 37.8 lb-ft (US English)

2-406

Engine Mechanical System JL4G18-D

Engine