Disassembly and Assembly: Assembly

• Use Genuine Silicone RTV Sealant or equivalent. Refer to "FLUIDS AND LUBRICANTS ".

• Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the bolts.

Fig 1: Inserting Oil Jet Dowel Pin Into Cylinder Block Dowel Pin Hole

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1. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
2. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
   • Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
   • Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.

Fig 2: Identifying Thrust Bearings Installation Position

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• Confirm the correct main bearings are used. Refer to "PISTON-TO-CYLINDER BORE CLEARANCE ".

Fig 3: Identifying Main Bearing

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• A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown.
• For d2, select the minimum diameter in the measuring area.
• If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.

  Limit (d1 - d2): 0.11 mm (0.0043 in) 

Fig 4: Identifying Main Bearing Cap Bolts Dimension

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Fig 5: Identifying Main Bearing Cap Bolts Tightening Sequence

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1. Make sure that the front marks on the main bearing beam faces the front of the engine.
   Fig 6: Identifying Main Bearing Front Marks

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2. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
3. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
4. Lubricate the threads and seat surfaces of the bolts with new engine oil.
5. Tighten the bolts in two stages:

Stage 1: 35 N.m (3.6 kg-m, 26 ft-lb) 

Stage 2: 90° - 95° degrees clockwise 

Tool number: KV10112100 (BT-8653-A) 

Fig 7: Checking Angle Of Main Bearing Cap Bolts

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• If beyond the limit, replace the bearing with a new one.

  Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) 

  Limit: 0.30 mm (0.0118 in) 

Fig 8: Checking Crankshaft End Play

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Tool number: WS3993000 (-) 

• Apply sealant to rear oil seal retainer as shown, using Tool. Use Genuine Silicone RTV Sealant, or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

Fig 9: Applying Sealant To Rear Oil Seal Retainer

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1. Install the snap ring into the pin-groove of the piston rear side, using suitable tool.
   • Insert it fully into groove to install.
   Fig 10: Identifying Piston Pin Snap Ring Into Front Of Piston

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2. Install the piston to the connecting rod.
   • Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° - 70°C (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
     Fig 11: Heating Piston

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   • Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. on the connecting rod are positioned as shown.
   Fig 12: Identifying Cylinder Number And Piston Grade Number

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3. Install the snap ring into the front of the piston pin-groove.
   • After installing, check that the connecting rod pivots smoothly on the pin.

Fig 13: Identifying Snap Ring Into Front Of Piston Pin-Groove

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• When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
• When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
• Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.

Fig 16: Identifying Connecting Rod Bearings To Connecting Rod

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• Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
• Match the cylinder position with the cylinder No. on the connecting rod to install.
• Install the piston with the front mark on the piston crown facing the front of the engine, using a suitable tool.

Fig 17: Installing Piston And Connecting Rod Assembly

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• Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
• Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
• Lubricate the threads and seat surfaces with new engine oil  .

Fig 18: Checking Connecting Rod Bushing Oil Clearance (Small End)

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• Measure the outer diameter of the connecting rod cap bolt as shown.

  Outer diameter "d" of the connecting rod bolt 

  Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) 

  Limit: 7.75 mm (0.3051 in) 

Fig 19: Identifying Connecting Rod Cap Bolt Outer Diameter

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Stage 1: 20 N.m (2.0 kg-m, 15 ft-lb) 

Stage 2: 90° - 95° degrees clockwise 

Tool number: KV10112100 (BT-8653-A) 

• Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
• After tightening the nuts, make sure that the crankshaft rotates smoothly.
• Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.

  Connecting rod side clearance: 

  Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) 

  Limit: 0.40 mm (0.0157 in) 

Fig 20: Measuring Connecting Rod Angle

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• Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
• Install the knock sensor with the connector facing the rear of the engine.
• Do not tighten the bolts while holding the connector.
• Make sure that the knock sensor does not interfere with other parts.

Fig 21: Identifying Knock Sensor

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Fig 23: Aligning Dowel Pin Of Crankshaft Rear End With Pin Holes

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• Install the drive plate and reinforce plate in the direction as shown.

Fig 24: Installing Drive Plate And Reinforcement Plate

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Tool number: KV10117700 (J-44716) 

• Tighten the drive plate (CVT) crosswise several times using suitable tool.

Fig 25: Identifying Transmission Bolt

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