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1.Assemble in the order indicated in the table.

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Thrust Bearing And Main Bearing Assembly Note

Thrust bearing

1.Apply clean engine oil to the thrust bearings.

2.Assemble the bearings with the oil groove of the thrust bearing pointed toward the sliding surface.

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Main bearing

1.Apply clean engine oil to the main bearings.

2.Align the positioning tab of the main bearing with the positioning groove of the lower and upper cylinder block, and assemble the bearings.

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Plate Assembly Note

1.Install the plate using the following procedure:

(1) Install the groove of the plate tooth to the position shown in the figure and temporarily tighten bolt A.

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(2)Temporarily tighten the bolt B.

(3)Install bolt C and tighten the bolts to the specified tightening torque in the order of C, B, and A.

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

Lower Cylinder Block Assembly Note

1.Completely clean and remove any oil, dirt, silicon sealant or other foreign matter that may be adhering to the lower cylinder block and cylinder block.

Caution

• Using bolts with the old silicon seal adhering could cause cracks in the cylinder block, etc.

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2.When reusing the lower cylinder block installation bolts, clean any old sealant from the bolts.

Caution

• Apply silicon sealant in a single, unbroken line.

• To prevent silicon sealant from hardening, adhere the engine front cover and the cylinder block firmly within 10 min. after applying silicon sealant. After adhering them, tighten the installation bolts immediately.

3.Apply silicon sealant (TB1217D or equivalent) to the lower cylinder block as shown in the figure.

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4.Install the lower cylinder block.

5.Tighten the lower cylinder block installation bolts using the following procedure:

(1)Apply clean engine oil to seating surface and thread of the lower cylinder block installation bolts A.

(2)Tighten the lower cylinder block installation bolts A in the order shown in the figure using the following procedure:

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Tightening procedure

1. 38—42 N·m {3.9—4.2 kgf·m, 29—30 ft·lbf}

2. Loosen all the bolts (until bolts are torque-free).

3. 24—28 N·m {2.5—2.8 kgf·m, 18—20 ft·lbf}

4. 57.5—62.5°

(3)Tighten the lower cylinder block installation bolts B in the order shown in the figure.

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Tightening torque

19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

6.After verifying that silicone sealant protrudes to the rear oil seal press-in part, wipe away the excess silicone sealant.

• If silicone sealant does not protrude to the rear oil seal press-in part, remove the lower cylinder block and apply silicone sealant again.

Piston Pin Assembly Note

1.Apply clean engine oil to the piston pin.

2.Insert the piston pin to the piston and connecting rod.

Note

• When assembling the piston to the connecting rod, each one can be assembled in either direction.

Snap Ring Assembly Note

Caution

• Do not compress the outer diameter of the snap ring more than necessary when assembling the snap ring (reference: 20.66 mm {0.8134 in} or less).

1.Insert a new snap ring using a thin plier.

Piston Ring Assembly Note

Note

• It is not required to position the end gap between the top ring and second ring.

1.Assemble the piston ring so that the end gap of each oil ring does not overlap as shown in the figure.

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2.Install the second ring with the notch facing downward.

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3.Install the top ring with the notch facing upward.

Connecting Rod Bearing Assembly Note

1.Apply engine oil to the connecting rod bearings.

2.Align the positioning tab of the connecting rod bearing with the positioning groove of the connecting rod and connecting rod cap, and assemble the bearings.

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Piston, Connecting Rod Assembly Note

1.Insert the piston into the cylinder with the mark on top of the piston facing the intake side.

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Connecting Rod Cap Assembly Note

1.Measure the length of the connecting rod cap bolt

• If it exceeds the maximum specification, replace the connecting rod cap bolt.

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2.Position so that the broken, rough faces of the connecting rods and connecting rod caps are aligned exactly, and assemble the connecting rod caps.

3.Tighten the connecting rod cap bolts in the following two steps.

Pilot Bearing Assembly Note

1.Install new pilot bearing to the specified position using the following tools.

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