Components

1. Rear oil seal 10. Piston 19. Cylinder block O-ring

2. Cylinder block cover [RH] 11. Piston ring (NO.1) 20. Piston cooling oil jet
2-a.9.8 - 11.8 N·m (1.0 - 1.2 kgf· 12. Piston ring (NO.2) 20-a. 8.8 - 10.8 N·m (0.9 -
m, 7.2 - 8.7 lb·ft) 13. Oil ring 1.1 kgf·m, 6.5 - 8.0 lb·ft)
3. Cylinder block cover [LH] 14. Lower crankcase 21. Sealing cap
3-a. 9.8 - 11.8 N·m (1.0 - 1.2 kgf· 14-a. 21.6 - 25.5 N·m (2.2 - 2.6 kgf·m, 22. Balance shaft
m, 7.2 - 8.7 lb·ft) 15.9 - 18.8 lb·ft) 23. LH Balance shaft sciss
4. Connecting rod bearing cap 14-b. 27.5 - 31.4 N·m (2.8 - 3.2 kgf·m, ors gear
4-a. 12.7 - 16.7 N·m (1.3 - 1.7 kgf 20.3 - 23.1 lb·ft) + (90 - 92°) + (60 - 6 23-a. 76.5 - 80.4 N·m (7.8
·m, 9.4 - 12.3 lb·ft) + (118 - 122° 2°) - 8.2 kgf·m, 56.4 - 59.3 lb·f
) 15. Crankshaft lower bearing t)
5. Connecting rod lower bearing 16. Crankshaft 24. RH Balance shaft gear
6. Connecting rod upper bearing 17. Crankshaft upper bearing 24-a. 76.5 - 80.4 N·m (7.8
7. Connecting rod 18. Crankshaft thrust bearing - 8.2 kgf·m, 56.4 - 59.3 lb·f
8. Snap ring t)
9. Piston pin 25. Intermediate scissors
gear
25-a. 93.2 N·m (9.5 kgf·m,
68.7 lb·ft)
26. Intermediate scissors
gear bolt
27. Cylinder block

DRIVE PLATE
Tightening torque :
117.7- 127.5 N·m (12.0 - 13.0 kgf·m, 86.8 - 94.0 lb·ft)

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Special Service Tools

Tool Name / Number Illustration

Sealing cap removal/installation tool

0K214-P2500
Sealing cap removal tool body
0K214-P2501
Sealing cap removal tool adapter
0K214-P2502
Sealing cap installer
0K214-P2503
Balance shaft fixing jig
0K214-P2600

Handle
09231 - H1100

Reassembly

• Clean the each part before assembling.

• Apply new engine oil on the rotating surface before assembling parts.

• Always use the new gasket, O-ring and oil seal.

1 Remove the sealing cap using SST (0K214 - P2501, 0K214 - P2502).
.
(1 Install the SST (0K214 - P2502) to the sealing cap.
)

Make sure the SST (0K214 - P2502) is seated on the end face of the sealing cap (A).
(2 Install the SST (0K214 - P2501) to the SST (0K214 - P2502), and tighten the nut (A) clockwise to secu
)

(3 Install SST (0K214 - P2501) and remove the sealing cap by tightening the nut (A) clockwise.
)
(4 Remove the sealing cap from the cylinder block following the procedure above.
)
2 Secure the balance shaft using SST (0K214 - P2600).
.
(1 Rotate the balance shaft to align the balance shaft groove at 12 o'clock.
)
[LH]

[RH]
 (2 Install the SST (0K214 - P2600).
)
Tightening torque :
7.8 N·m (0.8 kgf·m, 5.8 lb·ft)

3 Loosen the balance shaft bolt (A).

.
 Do not remove the balance shaft bolts (A).

4 Install the main bearing.

.
(1 Install the 5 crankshaft upper bearings (A) while aligning the groove of the cylinder block and the pro
)

When installing the crankshaft upper bearing, install the appropriate upper bearing on each journa
[#1, 5 Journal Upper Bearing]
 A : Mark
B : Color

[#2, 3, 4 Journal Upper Bearing]

A : Mark
B : Color

(2 Install the 5 crankshaft lower bearings (A) while aligning the groove of the lower crankcase and the p
)
 (3 Apply engine oil after assembling the main bearings.
)

5 Install the thrust bearings.

.
Install 2 thrust bearings under the cylinder block #4 journal part with the oil groove facing up.

6 Install the crankshaft.

.
(1 Install the crankshaft on the cylinder block.
)
(2 Make sure the crankshaft pin is at 6 o'clock. (No.1 cylinder TDC position)
)

(3 Install the crankshaft sprocket to check the crankshaft sprocket timing mark align with the cylinder b
)
 Install a SST (0K240 - P2200) on the crankshaft sprocket to check if the TDC is correct (No.1 cylinde

7 Install the balance shaft bolts (A).

.
Tightening torque :
76.5 - 80.4 N·m (7.8 - 8.2 kgf·m, 56.4 - 59.3 lb·ft)
8 Remove the SST (0K214 - P2600).
.

9 Install the sealing cap using the SST (0K214 - P2503, 09231 - H1100).
.
(1 Apply sealant (A) on the sealing cap mounting surface.
)
[Cylinder Block]
[Sealing cap]

• Do not reuse the sealing cap.

• After applying sealant (HENKEL LOCTITE 638, THREEBOND 1386T, CANLOK 962T) on the sealing

• Clean foreign substances and engine oil in the cylinder block sealing cap mounting hole.

• When applying sealant, apply it in the circumferential direction without interruption.

• If the sealant above is not used, durability cannot be guaranteed.

(2 Install the sealing cap (A) to the SST (0K214 - P2503, 09231 - H1100).
)

(3 Install the sealing cap by tapping SST (0K214-P2503, 09231-H1100) lightly with a hammer.
)

(4 Install the sealing caps (A) to the cylinder block following the procedure above.
)
10 Install the lower crankcase.
.
(1 Remove cured sealant, foreign matter, oil, dirt, moisture on the lower crankcase liquid gasket sealin
)
Spray the cleaner on the sealing surface and wipe it off with a clean cloth.

(2 Install a new O-rings (A) on the cylinder block.

)
(3 Assemble within 5 minutes after applying liquid gasket on the lower crankcase mounting surface.
)
Apply liquid gasket evenly at a time.

Bead width : Ø 2.5 - 3.5 mm (0.0984 - 0.1377 in.)

Seal type : FIPG TYPE AAO (MS721-40)

(4 Tighten the lower crankcase mounting bolts evenly several times in the order shown in the figure be
)
Tightening torque : 21.6 - 25.5 N·m (2.2 - 2.6 kgf·m, 15.9 - 18.8 lb·ft)
(5 Tighten the crankshaft bearing cap bolts evenly several times in the order shown in the figure below
)
Tightening torque : [27.5 - 31.4 N·m (2.8 - 3.2 kgf·m, 20.3 - 23.1 lb·ft) ] + [90
- 92°] + [60 - 62°]

Do not reuse the crankshaft bearing cap bolts.

(6 Remove the lower crankcase mounting bolts.

)
 (7 Tighten the lower crankcase mounting bolts evenly several times in the order shown in the figure be
)
Tightening torque : 21.6 - 25.5 N·m (2.2 - 2.6 kgf·m, 15.9 - 18.8 lb·ft)

(8 Make sure the crankshaft rotates smoothly.

)

11 Check the crankshaft end play.

.

12 Install the piston and connecting rod assembly.

.
(Refer to Cylinder Block - "Piston and Connecting Rod")

13 Install in the reverse order of removal.

.

In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according
Connecting rod bearing selection
(Refer to Cylinder Block - "Piston and Connecting Rod")

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Reassembly

• Clean the each part before assembling.

• Apply new engine oil on the rotating surface before assembling parts.

• Always use a new gasket, O-ring, and oil seal.

1 Assemble the piston and the connecting rod.

.
(1 Install the snap ring (A) in one side of the piston pin hole.
)

(2 Align the piston front mark (A) and the connecting rod front mark (B).
)
 (3 Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod
)

(4 Install the snap ring (B) in the other side after inserting the piston pin.
)

• Before assembling the piston pin, apply a sufficient amount of engine to the outer surface of pis

• When inserting, be careful not to damage or scratch the connecting rod small end hole, piston p

• Install the snap ring so that it contacts securely with the whole groove of the piston pin hole.

2 Install the piston rings.

.

(1 Install the oil ring and coil expander by hand.

)

(2 Using a piston ring expander, install the 2 compression rings with the mark facing upward.
)

(3 Install the piston rings so that the ends of each piston ring are as shown below.
)

A : Oil ring
B : No.1 ring
C : No.2 ring
D : Coil expander

3 Install the connecting rod bearing.

.
(1 Align the groove of the connecting rod bearing cap (A) with the bearing (B) protrusion.
)
4 Install the piston and connecting rod assembly.
.

• Apply a small amount of engine oil to the piston ring groove and cylinder bore before installing the

• Make sure that the front mark (A) of the piston and the front mark (B) of the connecting rod facing t

(1 Install the piston ring compressor, making sure that the piston rings are securely seated. Insert the p
) e piston.

(2 When the piston ring is inserted into the cylinder, stop inserting and check the alignment of the journ
)
 While inserting the piston, press the piston ring compressor to prevent the piston ring from expand

(3 Install the connecting rod cap (A) and tighten the bolts to the specified torque.
)
Tightening torque :
[12.7 - 16.7 N·m (1.3 - 1.7 kgf·m, 9.4 - 12.3 lb·ft) ] + [118 - 122°]

Always use new connecting rod bearing cap bolts.

5 Install in the reverse order of removal.

.

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Cylinder Block Journal Bore Inner Diameter

Classification Mark Cylinder block journa

a A 64.000 - 64.006 mm (2.

b B 64.006 - 64.012 mm (2.

c C 64.012 - 64.018 mm (2.

Crankshaft Main Journal Classification Mark Location

Crankshaft Main Journal Classification Table

Classification Mark Main journal outer diam

I 1 54.994 - 55.000 mm (2.16

II 2 54.988 - 54.994 mm (2.16

III 3 54.982 - 54.988 mm (2.16

Crankshaft Bearing Classification Mark Location

[#1, 5 Journal Upper Bearing]
A : Mark
B : Color
[#2, 3, 4 Journal Upper Bearing]
A : Mark
B : Color

[Lower Bearing]
A : Mark
B : Color
Crankshaft Bearing Classification Table

Classification Color

A Light blue

B Black

C Pink

D Light green

E White

(1 Refer to the bearing selection table below to select the suitable crankshaft main bearing.
0)
Crankshaft main bearing selection table

Main journal bore clas

A(A)

Crankshaft main journal I (1) A

classification mark (Light blue)

II (2) B
(Black)

III (3) C
(Pink)

2 Measure the crankshaft end play.

.
Check the axial clearance by moving the crankshaft back and forth using a dial gauge.
 Crankshaft end play : 0.100 - 0.280 mm (0.00393 - 0.01102 in.)

If end play exceeds limit value, replace the thrust bearing.

Thrust bearing thickness : 1.925 - 1.965 mm (0.0757 - 0.0773 in.)

3 Check the crankshaft main journals and pin journals.

.
Measure the outer diameter of the main journals and pin journals using micro meter.

Main journal outer diameter (A) : 54.982 - 55.000 mm (2.1646 - 2.1653 in.)
Pin journal outer diameter (B) : 51.982 - 52.000 mm (2.0465 - 2.0472 in.)