CAUTION: Do not reuse snap rings, always replace with new ones.
Heat the pistons to 60° - 70 °C (140° - 158 °F) .
Push out the piston pin with a suitable tool, with an outer diameter approximately 20 mm (0.8 in) .
Remove the rear oil seal retainer from the cylinder block.
Insert a screwdriver or similar tool between the rear end of the crankshaft counter weight and rear oil seal retainer, and separate the liquid gasket to remove.
CAUTION: Be careful not to damage the mating surface.
Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the bolts.
Install the main bearings and the thrust bearings.
Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
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.
Set the upper main bearings in their proper positions on the cylinder block.
Confirm the correct main bearings are used. Refer to See: Inspection.
Instructions for the re-use of the main bearing cap bolts.
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)
After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts. Tighten the bearing cap bolts in the numerical order as shown.
Make sure that the front marks on the main bearing beam faces the front of the engine.
Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
Lubricate the threads and seat surfaces of the bolts with new engine oil.
Tighten the bolts in two stages:
CAUTION: Measure the tightening angle in stage 2 using Tool. Do not measure visually.
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.
Assemble so that the piston front mark (B) on the crown and the oil hole (C), connecting rod front mark (D) and Cylinder No. (E) on the are positioned as shown.
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.
Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
Install the pistonconnecting 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.
Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.
Measure the outer diameter of the connecting rod cap bolt as shown.
Tighten the connecting rod nuts in two stages using Tool:
CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
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.
Install the baffle plate to the main bearing beam.
Install the knock sensor.
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.
CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
Install the pilot bushing (M/T) or converter (CVT) as shown.
Install the flywheel (M/T), if equipped.
When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
Install the drive plate (CVT), if equipped.
Install the drive plate and reinforce plate in the direction as shown.
Align dowel pins of crankshaft rear and drive plate with pin holes of each part.