Crankshaft and Piston Installation

Crankshaft and Piston Installation

Special Tools Required

- Driver Handle, 15 x 135L 07749-0010000
- Driver Attachment, 106 mm 07OAD-RCAA200

1. Check the main bearing clearance with plastigage Service and Repair.

2. Check the connecting rod bearing clearance with plastigage Service and Repair.

3. Install the bearing halves in the engine block and the connecting rods.

4. Apply new engine oil to the inside of the main bearings and the connecting rod bearings.

5. Install the CKP pulse plate to the crankshaft CKP Pulse Plate Replacement.

6. Lower the crankshaft (A) into the engine block, being careful not to damage the journals and the CKP pulse plate (B).






7. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 3 journal.






8. Install the main bearings (A) and the main bearing caps (B) with the arrow (C) facing the timing belt side of the engine block.





9. Apply new engine oil to the bolt threads and flanges, then loosely install the bearing cap bolts (D) and the bearing cap side bolts (E).

10. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in.

11. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore.

12. Attach the ring compressor to the piston/connecting rod assembly, and check that the bearing is securely in place.

13. Position the piston/connecting rod assembly with the arrow (A) facing the timing belt side of the engine block.






14. Position the piston/connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.





15. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.

16. Measure the diameter of each connecting rod bolt at point A and point B.





17. Calculate the difference in diameter between point A and point B.









18. If the difference in diameter is out of tolerance, replace the connecting rod bolt.

19. Install the connecting rod bearing (A), then line up the mark (B) on the connecting rod (C) and the cap (D).






20. Apply new engine oil to the bolt threads and flanges. Torque the bolts (B) to 20 Nm (2.0 kg-m, 14 lb-ft).

21. Tighten the connecting rod bolt an additional 90 °.

NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 16 of the procedure. Do not loosen it back to the specified angle.






22. Tighten the main bearing cap bolts, then tighten the main bearing cap side bolts to the specified torque in the sequence as shown. Repeat the torque sequence again to ensure the bolts are properly torqued.






23. Remove all of the old liquid gasket from the engine block end cover mating surfaces, the bolts, and the bolt holes.

24. Clean and dry the engine block end cover mating surfaces and the crankshaft oil seal housing.

25. Apply a light coat of new engine oil to the lip of the crankshaft oil seal.

26. Using the driver handle, 15 x 135L and the oil seal driver attachment, 106mm, drive in the new crankshaft oil seal (A) until the oil seal driver attachment bottoms on the engine block end cover.






27. Apply liquid gasket (P/N 08717-0004, 08718-0003, 08718-0004, or 08718-0009) to the engine block mating surface of the engine block end cover and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





28. Install the dowel pins (A), a new O-ring (B), and the engine block end cover (C) on the engine block.

NOTE:

- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the engine block end cover.





29. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.

30. Install a new crankshaft oil seal in the oil pump.

31. Remove all of the old liquid gasket from the oil pump mating surfaces, bolts, and bolt holes.

32. Clean and dry the oil pump mating surfaces.

33. Apply liquid gasket (P/N 08717-0004, 08718-0003, 08718-0004, or 08718-0009) to the engine block mating surface of the oil pump and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
- If you apply liquid gasket P/N 087178-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





34. Apply a light coat of new engine oil to the lip of the crankshaft oil seal, and to the new O-ring (A).





35. Install the dowel pins (B), then align the inner rotor with the crankshaft, and install the oil pump (C).

NOTE:

- Wait at least 30 minutes before filling the engine with oil.
- Do not run the engine for at least 3 hours after installing the engine block end cover and the oil pump.

36. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.

37. Install the baffle plate (D), then install the oil strainer (E) with the new O-ring (F).

38. Install the rocker arm oil control solenoid/oil filter assembly (A), with a new rocker arm oil control solenoid filter (B).





39. Install the oil pan Engine Oil Pan Installation.

40. Install the timing belt drive pulley to the crankshaft Service and Repair.

41. Install the cylinder heads Cylinder Head Installation.

42. Install the drive plate Service and Repair.

43. Install the transmission Automatic Transmission Installation.

44. Install the engine/transmission Engine Installation.

NOTE: When any crankshaft or connecting rod bearing is replaced, after assembly it is necessary to run the engine at idling speed until it reaches normal operating temperature, then continue to run it for about 15 minutes.