Assembling Short Block; Assembling Crankshaft - TOHATSU TLDI 40 Service Manual

Assembling Short Block

Assemble in reverse order of disassembly.
Apply genuine engine oil to the following parts.
Big end of connecting rod
Small end of connecting rod and pin boss oil hole
Main bearing
Piston ring and entire circumference of piston
Entire surface of cylinder bore
Upper bearing O-ring
Line up piston ring end gap with knock pin.

Assembling Crankshaft

Desrease the surface of the crankcase
Assemble the crankshaft and the cylinder using the
following procedures.
Points to Note:
Make sure that all pistons are positioned
perpendicularly; then insert piston in perpendicular
direction using gentle jiggling motion.
Make sure pistons are not twisted in horizontal
direction.
Take the following steps prior to completing assembly
of the crankshaft.
• Install thrust plates at 2 locations.
• Line up the bearing knock position.
Insert in groove on mating surface.
• Lining up position of upper bearing
Line up of the knock holes on the upper bearing
with the knock pins on the journal of the cylinder.
Gently move the upper bearing to confirm it is
correctly positioned on the knock pins.
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