1. Install:
- Top ring «1»
- 2nd ring «2»
- Upper oil ring rail «3»
- Oil ring expander «4»
- Lower oil ring rail «5»
Note: Be sure to install the piston rings so that the manufacturer’s marks or numbers «a» face up.
2. Install:
- Piston «1» (onto the respective connecting rod «2»)
- Piston pin «3»
- Piston pin clip «4»
Notes:
- Apply engine oil onto the piston pin.
- Make sure that the «Y» mark «a» on the connecting rod faces left when the arrow mark «b» on the piston is pointing up as shown.
- Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4).
3. Lubricate:
- Piston
- Piston rings
- Cylinder (with the recommended lubricant)
Recommended lubricant: Engine oil.
4. Offset:
- Piston ring end gaps
a. Top ring; b. Lower oil ring rail; c. Upper oil ring rail; d. 2nd ring; e. Oil ring expander
5. Lubricate:
- Crankshaft pins
- Big end bearings
- Connecting rod big end inner surface (with the recommended lubricant)
Recommended lubricant: Engine oil.
6. Check:
- Cylinder stud bolts «1»
Cylinder stud bolt: 8 Nm (0.8 m·kg, 5.8 ft·lb).
7. Install:
- Cylinder gasket «2»
8. Install:
- Big end bearings (onto the connecting rods and connecting rod caps)
Notes:
- Align the projections «a» on the big end bearings with the notches «b» in the connecting rods and connecting rod caps.
- Be sure to reinstall each big end bearing in its original place.
- Make sure that the characters «c» a on both the connecting rod and connecting rod cap are aligned.
9. Tighten:
- Connecting rod bolts
Connecting rod bolt: 29.4 Nm (3.0 m·kg, 21 ft·lb).
Notes:
- Install by carrying out the following procedures in order to assemble in the most suitable condition.
- First tighten the bolts to 15 Nm (1.5 mrkg, 11 ft·lb)
- Retighten the bolts to 29.4 Nm (3.0 m·kg, 21 ft·lb)
a. Replace the connecting rod bolts with new ones.
b. Clean the connecting rod bolts.
c. After installing the big end bearing, assemble the connecting rod and connecting rod cap once using a single unit of the connecting rod.
d. Tighten the connecting rod bolt while checking that the sections shown «a» and «b» are flush with each other by touching the surface.
Note: To install the big end bearing, care should be taken not to install it at an angle and the position should not be out of alignment.
a. Side machined face; b. Thrusting faces (4 places at front and rear)
e. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition.
10. Install:
- Piston assemblies «1» (into the cylinder)
Note: While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand.
11. Install:
- Cylinder assembly «1»
- Connecting rod caps «2»
Notes:
- Make sure that the «Y» marks «a» on the connecting rods face towards the left side of the crankshaft.
- Make sure that the characters on both the connecting rod and connecting rod cap are aligned.
12. Tighten:
- Connecting rod bolts
Connecting rod bolt: 20 Nm (2.0 m·kg, 14 ft·lb) + 150°.
Caution! Tighten the connecting rod bolts using the plastic-region tightening angle method.
a. Clean the connecting rod bolts.
b. Tighten the connecting rod bolts.
c. Put a mark «1» on the connecting rod bolt «2» and the connecting rod cap «3».
d. Tighten the bolt further to reach the specified angle (150°).
e. After the installation, check that the section shown «a» is flush with each other by touching the surface.
a. Side machined face
Warnings!
- When the bolt is tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and perform the procedure again.
- If they are not flush with each other, remove the connecting rod bolt and big end bearing and restart from step «9». In this case, make sure to replace the connecting rod bolt.
Cautions!
- Do not use a torque wrench to tighten the bolt to the specified angle.
- Tighten the bolt until it is at the specified angles.