Crankcases - Assembly

Perform the following operations

Perform the following operations:

  1. Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth.
  2. Make sure that the transmission is in neutral.
  3. Make sure that the three locating dowels are in position in the upper crankcase.
    4. Three locating dowels cdmx

    1. Locating dowels

  4. Apply a thin bead of silicone sealant (at the factory, ThreeBond 1216E is used) to the lower crankcase mating faces.
    5. Apply sealant to crankcase cdmy

    Sealant Areas

    caution
    Do not use excessive amounts of sealant.The excessive sealant may become dislodged and could block the oil passages in the crankcases causing severe engine damage.
    caution
    Make sure the three piston cooling jets are installed.If the piston cooling jets are omitted, oil pressure will be reduced.Running the engine with low oil pressure will cause severe engine damage.
  5. Install and lubricate the crankshaft bearing shells with a 50/50 solution of engine oil and molybdenum disulphide grease (see Connecting Rod Big End Journal Checking, Measuring and Bearing Selection before proceeding).
  6. Lubricate the crankshaft journals with clean engine oil.
  7. Fit the crankshaft (see Crankshaft - Installation).
  8. If removed, refit the balancer (see Balancer - Installation).
  9. Position the lower crankcase to the upper. An assistant may be required to support the crankcase during alignment.
  10. Fit the bolts into the lower crankcase and hand tighten until the bolt heads are near contact with the crankcase. Note the position of the hardened washers under bolts 1 to 8.
    11. notice
    The crankcase screws are tightened in stages.Two different sizes of crankcase bolts are used. All bolts must be tightened in the four stages that follow:
    caution
    Failure to follow the correct bolt tightening sequence can result in permanent crankcase damage.

Stage 1

  1. In the sequence shown below, tighten the crankcase bolts 9 to 26 to 12 Nm.
    2. LG1 crankcase tighten 9 to 26

    Crankcase Bolt 9 to 26 Tightening Sequence

Stage 2

  1. In the sequence shown below, tighten the new crankcase bolts 1 to 8 to 10 Nm.
    2. LG1 crankcase tighten 1 to 8

    Crankcase Bolt 1 to 8 Tightening Sequence

Stage 3

  1. In the sequence shown below, tighten the crankcase bolts 1 to 8 to 70° of bolt rotation using the service tool T3880105 :
    2. LG1 crankcase tighten 1 to 8

    Crankcase Bolt 1 to 8 Tightening Sequence

    T3880105

    T3880105 - Torque Angle Gauge

Stage 4

  1. In the sequence shown below, tighten the crankcase bolts 14 to 19 to 32 Nm.
    2. LG1 crankcase tighten 14 to 19

    Crankcase Bolt 14 to 19 Tightening Sequence

Perform the following operations

Perform the following operations:

Sump - Install L Series

Camshaft Cover - Install L Series

Clutch - Install L Series

Engine - Install - L Series