Disassembly And Assembly: Assembly

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• Apply liquid gasket to the thread of water drain plug (2).

  Use Genuine Silicone RTV Sealant, or equivalent. Refer to  RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  . 

  CAUTION:

  Do not reuse washer.

  : Engine front

• Tighten each plug as specified below.

1. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.
2. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.

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   : Engine front

   • Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
3. Install the main bearings paying attention to the direction.
   • Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
   • When installing, align main bearing to the center position of cylinder block and main bearing cap.
   • Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.

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     NOTE:

     For assembly, the center position can be visually identified.

   • To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off the cylinder block chamfer.
   • To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off bearing cap chamfer.

1. Set the signal plate (1) with the flange facing toward the counterweight side (engine front side) to the crankshaft rear surface.

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   (A)	: Dowel pin hole

2. After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt.
   NOTE:

   Dowel pin of crankshaft and signal plate is provided as a set for each.

3. Remove dowel pin.
   CAUTION:

   Be sure to remove dowel pin.

• While turning crankshaft by hand, check that it turns smoothly.

• Install the main bearing cap while referring to the front mark (B) and the journal number stamp (A).

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  : Engine front

  NOTE:

  Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.

Fig 1: Main Bearing Cap Bolts Tightening Sequence

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: Engine front

1. Apply new engine oil to threads and seat surfaces of the bolts.
2. Tighten main bearing cap bolts in numerical order.

   Step 1	: 32.4 N•m (3.3 kg - m, 24 ft - lb)
   Step 2	: 60° clockwise

3. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order as shown.
   Fig 2: Main Bearing Cap Bolts Tightening Sequence

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   CAUTION:

   Check and confirm the tightening angle by using the Tool (A) or protractor. Do not judge by visual inspection without the Tool (A).

   Tool number (A)

   : KV10112100 (BT-8653-A)

   • After installing the main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.
   • Check crankshaft end play. Refer to INSPECTION .

1. Using a heat gun, heat the piston until the piston pin can be pushed in by hand without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod.
2. Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position as shown.

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   (B)	: Oil hole
   (D)	: Connecting rod big end grade

   CAUTION:

   Press-fit the piston so as not to damage it.

   NOTE:

   • The joint between the connecting rod and the piston pin is a press fit.
   • The symbols without notes are for manufacturing.
   • Press-fit the piston pin (2) from piston surface (A) to the depth of 2.35 mm (0.092 in) (b).

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     (1)	: Connecting rod
     	: Press-fit direction

   • After finishing work, check that the piston (3) moves freely.

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• Position each ring with the gap as shown referring to the piston front mark (B).

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  (A)	: Oil ring upper or lower rail gap (either of them)
  (C)	: Second ring and oil ring spacer gap
  (D)	: Top ring gap

• Install second ring with the stamped mark (E) facing upward.

  Stamped mark:
  	Top ring	: 1R
  	Second ring	: 2R

• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
• Install the bearing in the center position.
  NOTE:

  There is no stopper tab.

• Check that the oil holes on connecting rod and connecting rod bearing are aligned.
• Install the connecting rod in the dimension (A) as shown.

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  (1)	: Connecting rod
  (2)	: Connecting rod bearing (upper)
  (3)	: Connecting rod bearing (lower)
  (4)	: Connecting rod cap
  (A)	: 1.7 - 2.1 mm (0.067 - 0.083 in)
  	: Engine front

  NOTE:

  Install the connecting rod bearing in the center position with the dimension as shown. For service operation, the center position can be checked visually.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Using Tool (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine.

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  CAUTION:

  • Do not damage mating surface with connecting rod cap.
  • Do not damage the cylinder wall or crankshaft pin.

  Tool number (A)

  : EM03470000 (J-8037)

• Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.

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  (A)	: Front mark
  (B)	: Oil hole
  (D)	: Connecting rod big end grade

1. Apply new engine oil to the threads and seats of connecting rod bolts.
2. Install connecting rod bolts in several steps.

   Step 1	Tighten to	: 27.4 N•m (2.8 kg - m, 20 ft - lb)
   Step 2	Completely loosen	: 0 N•m (0 kg - m, 0 ft - lb)
   Step 3	Tighten to	: 19.6 N•m (2.0 kg - m, 14 ft - lb)

3. Then turn all connecting rod bolts 60 degrees clockwise (angle tightening).
   CAUTION:

   Check and confirm the tightening angle by using the Tool (A) or protractor. Avoid judgement by visual inspection without the Tool (A).

   Tool number (A)

   : KV10112100 (BT-8653-A)

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   • After tightening connecting rod bolt, check that crankshaft rotates smoothly.
   • Check the connecting rod side clearance. Refer to INSPECTION .

M/T models

• Secure crankshaft with a stopper plate and tighten bolts crosswise over several times.

  Tool number

  : KV11105210 (J-44716)

CVT models

• Secure crankshaft with a stopper plate and tighten bolts crosswise over several times.

  Tool number

  : KV11105210 (J-44716)

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: Engine front

• Install connectors so that they are positioned toward the rear of the engine.

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• Tighten bolts with sensor inserted completely.

: Engine front