Crankshaft and Piston Installation

Installation

Special Tools Required
- Driver 07749-0010000
- Oil seal driver attachment, 80 mm I.D. 07VAD-P8A010A





1. Measure the diameter of each connecting rod bolt at point A and point B.
2. Calculate the difference in diameter between point A and point B.
Point A-Point B = Difference in Diameter
Difference in Diameter: Specification: 0 - 0.1 mm (0 - 0.004 inch)
3. If the difference in diameter is out of tolerance, replace tide connecting rod bolt.
4. Check the connecting rod bearing clearance with plastigage.
5. Check the main bearing clearance with plastigage.
6. Install the bearing halves in the cylinder block and connecting rods.
7. Apply engine oil to the main bearings and rod bearings.





8. Lower the crankshaft (A) into the block.





9. Oil the thrust washer surfaces. Install the thrust washers (A) in the No. 3 journal.





10. Install the bearings (A) and bearing caps (B) with the arrow (C) facing the timing belt end of the engine.
11. Apply engine oil to the bolt threads and flanges, then install the bearing cap bolts (D) and bearing cap side bolts (E).
12. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in.
13. Remove the connecting rod cap. Install the ring compressor, and check that the bearing is securely in place.





14. Position the piston with the arrow (A) facing the timing belt side of the engine.





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





17. Line up the mark (A) on the connecting rod and cap then install the cap.
18. Apply engine oil to the bolt threads. Torque the bolts (B) to 20 Nm (2.0 kgf-cm, 14 ft. lbs.).





19. Mark the connecting rod (A) and bolt head (B) as shown.
20. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 90°).





21. Tighten the bearing cap bolts and the bearing cap side bolts two turns at a time.
22. The seal mating surface on the engine block end cover should be dry. Apply a light coat of grease to the crankshaft and to the lip of the seal.





23. Drive the crankshaft oil seal squarely into the engine block end cover.





24. Confirm that the clearance is equal all the way around with a feeler gauge.
Clearance: 0.5 - 0.8 mm (0.02 - 0.03 inch)
25. Remove old liquid gasket from the engine bock end cover mating surfaces, bolts and bolt holes.
26. Clean and dry the engine block end cover mating surfaces.





27. Apply liquid gasket, P/N 08718-0001 or 08718-0003, evenly to the block mating surface of the engine block end cover and to the inner threads of the bolt holes. Install the dowel pins (A), new O-ring (B), and the engine block end cover (C) on the cylinder block.

NOTE: Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.

28. Remove old liquid gasket from the oil pump mating surfaces, bolts and bolt holes.
29. Clean and dry the oil pump mating surfaces.





30. Install the oil pump (A).
-1 Install a new crankshaft oil seal in the oil pump.
-2 Apply liquid gasket, P/N 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes.

NOTE: Do not install the parts if 5 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.

-3 Grease the lip of the oil seal and apply oil to the new O-rings (B).
-4 Install the dowel pins (C), then align the inner rotor with the crankshaft and install the oil pump.
-5 Clean the excess grease off the crankshaft and check the seal for distortion.
31. Install the baffle plate (D), then install the oil screen (E).
32. Install the oil pan.





33. Install the timing belt drive pulley (A), then install the crankshaft position (CKP) sensor (B).
34. Install the cylinder heads.
35. Install the transmission.
36. Install the engine assembly.

NOTE: Whenever any crankshaft 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 about 15 minutes.