Assembly
PISTON INSTALLATIONOil: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
1. If the crankshaft is already installed:
- Remove the connecting rod caps and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
- Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
- Stop tapping after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing piston into place.
- Install the rod caps with bearings, and torque the nuts to 32 Nm (24 ft. lbs.).
2. If the crankshaft is not installed:
- Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
- Position all pistons at top dead center.
NOTE: Maintain downward force on the ring compressor to prevent rings from expanding before entering the cylinder bore.
CRANKSHAFT
Oil: Before installing the crankshaft, apply a coat of engine oil to the main bearings and rod bearings.
1. Insert bearing halves in the cylinder block and connecting rods.
2. Install the thrust washers in the No. 4 journal. Oil the thrust washer surfaces.
3. Lower the crankshaft into the cylinder block, seating the rod journals into connecting rods No. 1, No. 2 and No. 5. Install the rod caps and nuts finger-tight outward.
4. Rotate the crankshaft clockwise, seat journals into connecting rods No. 3 and No. 4, and install the rod caps and nuts finger tight.
NOTE: Install caps so the bearing recess is on the same side as the recess in the rod.
5. Check rod bearing clearance with plastigage, then torque the cap-nuts.
32 Nm (24 ft. lbs.)
NOTE:
- Reference numbers on connecting rod are for big-end bore tolerance and do not indicate the position of piston in the engine.
- Coat the bolt threads with engine oil.
Main Bolt Torque Sequence:
6. Install the main bearing caps. Check clearance with plastigage, then tighten the bearing cap bolts in two steps. In the first step, torque all bolts in sequence to about 29 Nm (22 ft. lbs.); in the final step, torque in same sequence to 74 Nm (54 ft. lbs.).
NOTE: Coat the bolt threads with engine oil.
CAUTION: Whenever any crankshaft bearing or connecting rod bearing is replaced, it is necessary after reassembly to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for approximately 15 minutes.
7. Apply liquid gasket to the cylinder block mating surface of the rear cover, then install it on the cylinder block.
NOTE:
- Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- Apply liquid gasket evenly, being careful to cover all the mating surface.
- To prevent oil leakage, apply liquid gasket to the inner threads of the bolt holes.
- Do not apply liquid gasket to O-ring grooves.
- Do not install the parts if five minutes or more have elapsed since applying liquid gasket.
Instead reapply liquid gasket after removing old residue.
- After assembly, wait at least 30 minutes before filling the engine with oil.
- Apply a light coat of oil to the crankshaft and to the lip of seal. Use a new O-ring and apply oil when installing it.
8. Apply liquid gasket to the cylinder block mating surface of the oil pump, then install it on the cylinder block.
NOTE: Do not apply liquid gasket to O-ring grooves.
NOTE:
- Apply a light coat of oil to the crankshaft and to the lip of seal.
- Use new O-rings and apply oil when installing them.
9. Install the oil screen.
10. Apply liquid gasket to the cylinder block, then install the oil pan.
11. Torque the oil pan bolts and nuts as shown.
12. Install the oil pan inner pipe, then install the set plate.
CRANKSHAFT OIL SEALS
Installation (Engine Removal Not Required)
NOTE: The crankshaft housing surface should be dry.
Apply a light coat of grease to the crankshaft and to the lips of the seals.
1. Using the special tool, drive in the front crankshaft oil seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft, and check that the front crankshaft oil seal lip is not distorted.
2. Measure the flywheel-end seal thickness and the oil seal housing depth. Using the special tool, drive the rear crankshaft oil seal into the rear cover to the point where the clearance between the bottom of the rear crankshaft oil seal and the rear cover is 0.5 -0.8 mm (0.02 - 0.03 inch).
NOTE: Align the hole in the driver attachment with the pin on the crankshaft.