Engine Unit: Disassembly and Assembly: Assembly

Fig 1: Drain Plugs With Torque Specifications

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• Use Genuine Silicone RTV Sealant, or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ]
• Replace the copper washers with new ones.

Fig 2: Identifying Thrust Bearing, Thrust Bearing Attachment Point And Oil Groove

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1. Remove dust, dirt, and engine oil from the bearing mating surfaces of the cylinder block and lower cylinder block.
2. Install the thrust bearings to both sides of the No. 3 main bearing journal on the cylinder block.
   • Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
3. Install the main bearings paying attention to their position and direction.
   Fig 3: Position Of Installing Main Bearings

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   • The main bearing with an oil hole and groove goes on the cylinder block. The one without them goes on the lower cylinder block.
   • Only the main bearing (on the cylinder block) for No. 3 journal has different specifications.
   • Before installing the bearings, apply engine oil to the bearing friction surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
   • When installing, align the bearing stopper to the notch.
   • Make sure that the oil holes on the cylinder block and those on the corresponding bearing are aligned.

Fig 4: Identifying Signal Plate And Crankshaft

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1. Position the crankshaft and signal plate using a positioning dowel pin, and tighten the signal plate bolts to specification.

   Signal plate bolts 

   Type 1: 18.5 N.m (1.9 kg-m, 14 ft-lb) 

   Type 2: 22.0 N.m (2.2 kg-m, 16 ft-lb) 

2. Remove the dowel pin.
   CAUTION: Be sure to remove dowel pin before installing the crankshaft.
   NOTE: Dowel pins for the crankshaft and signal plate are supplied as a set for each.

• While turning the crankshaft by hand, check that it turns smoothly.
  CAUTION: Do not install rear oil seal at this time.

Fig 5: Identifying Liquid Gasket Applying Specifications On Lower Cylinder Block

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Tool number: WS39930000 (-) 

• Use Genuine RTV Silicone Sealant, or equivalent. Refer to [RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ]
  CAUTION: After liquid gasket is applied, the lower cylinder block installation must be finished within 5 minutes.
  NOTE: Cylinder block and lower cylinder block are machined together. Neither of them can be replaced separately.

Fig 6: Tightening Order Of Lower Cylinder Block Bolts

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Tool number: KV10112100 (BT-8653-A) 

Fig 7: Installing Oil Seal Using Suitable Drift

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• Install new oil seal in the direction shown.
  Fig 8: Identifying Oil Seal Lip And Dust Seal Lip Orientation For Installing Oil Seal

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  Fig 9: Identifying Rear Oil Seal Projection

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  CAUTION: Check tightening angle using Tool. Do not tighten by visual inspection.
  Fig 10: Checking Tightening Angle Using Tool

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  Tool number: KV10112100 (BT-8653-A) 

• Wipe off completely any protruding Silicone RTV Sealant on the exterior of engine.
• Check crankshaft side clearance. Refer to [SERVICE DATA AND SPECIFICATIONS ].
• After installing the bolts, make sure that the crankshaft can be rotated smoothly by hand.

1. Using a snap ring pliers, install the snap ring into the grooves of the piston's rear side.
   • Insert the piston pin snap ring fully into groove.
2. Install the piston to the connecting rod.
   • Using a heat gun, heat the piston [approximately 60° - 70°C (140° - 158°F)] until the piston pin can be pushed in by hand without excessive force. From the front to the rear, insert the piston pin into the piston and the connecting rod.
   • 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 11: Positioning Front Mark On Piston Crown And Oil Holes And Cylinder No. On Connecting Rod

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3. Install the piston pin snap ring into the front of the piston.
   • Check that the connecting rod moves smoothly.

Fig 12: Position Of Installing Piston Rings

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• Position each ring with the gap as shown, referencing the piston front mark as the starting point.
• Install the top ring and the second ring with the stamped surface facing upward.

  Stamped mark: 2ND (second ring) 

Fig 13: Identifying Cutout On Connecting Rod Bearing

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

Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft

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• Rotate the crankshaft so the pin corresponding to the connecting rod to be installed is at the bottom dead center position.
• Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
• Match the cylinder position number with the cylinder No. on the connecting rod for installation.
• Install the piston with the front mark on the piston crown facing the front of the engine using Tool.

  Tool number: EM03470000 (J-8037) 

  CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

Fig 15: Position Of Installing Connecting Rod Bearing Caps

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

Fig 16: Tightening Connecting Rod Bolts Using Tool

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Tool number: KV10112100 (BT-8653-A) 

• Apply engine oil to the threads and seats of the connecting rod bolts.
  CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.

  Step 1: 27.4 N.m (2.8 kg-m, 20 ft-lb) 

  Step 2: 0 N.m (0 kg-m, 0 ft-lb) 

  Step 3: 19.6 N.m (2.0 kg-m, 14 ft-lb) 

  Step 4: 85° - 95° (target 90° degrees) 

• Check the connecting rod side clearance. Refer to [ENGINE UNIT: INSPECTION AFTER DISASSEMBLY ].
• After tightening the bolts, make sure that the crankshaft rotates smoothly.

Fig 17: Identifying Crankshaft Rear End And Drive Plate

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• Install drive plate, reinforcement plate and pilot converter as shown.
• Using a drift with 33 mm (1.30 in) diameter, push pilot converter into the end of the crankshaft.
• Press fit pilot bushing into the crankshaft as shown; using a suitable drift of 19 mm (0.75 in)

Cylinder block heater: 73.5 N.m (7.5 kg-m, 54 ft-lb) 

Fig 18: Position Of Installing Knock Sensor

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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 lower left by 45° as shown.
• Do not tighten the knock sensor bolt while holding the connector.
• Make sure that the knock sensor does not interfere with other components.

  Knock sensor bolt: 21.1 N.m (2.2 kg-m, 16 ft-lb) 

  CAUTION: If the knock sensor is dropped, replace it with new one.

Crankshaft position sensor bolt: 7.0 N.m (0.71 kg-m, 62 in-lb)