Assembly
Special Tools Required- Driver 07749-0010000
- Oil Seal Driver Attachment, 80 mm I.D. 07VAD-P8A010A
1. Apply engine oil to the main bearings and rod bearings.
2. Install the bearing halves in the cylinder block and connecting rods.
3. Lower the crankshaft (A) into the block.
4. Oil the thrust washer surfaces. Install the thrust washers (A) in the No.3 journal.
5. Install the bearings (A) and bearing caps (B) with the arrow (C) facing the timing belt end of the engine.
6. Apply engine oil to the bolt threads and flange, then install the bearing cap bolts (D) and bearing cap side bolts (E).
7. Check the main bearing clearance with plastigage.
8. Set the crankshaft to BDC for the cylinder you are working on.
9. Remove the connecting rod caps. Install the ring compressor, and check that the bearing is securely in place.
10. Install the piston with the arrow (A) facing the timing belt side of the engine.
11. 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.
12. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
13. Check the connecting rod bearing clearance with plastigage.
14. Line up the mark (A) on the connecting rod and cap, then install the cap.
15. Apply engine oil to the bolt threads. Torque the bolts (B) to 20 Nm (20 kfg.m, 14 ft. lbs.).
16. Mark the connecting rod (A) and bolt head (B) as shown.
17. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 90°).
18. Torque the bearing cap bolts (A), then torque the bearing cap side bolts (B). Follow the numbered sequence shown.
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 approximately 15 minutes.
19. The seal mating surface on the engine block end cover should be dry.
20. Drive the crankshaft oil seal securely into the left side cover.
21. Confirm that the clearance is equal all the way around with a feeler gauge.
22. Clean and dry the left side cover mating surfaces. Apply a light coat of grease the crankshaft and to the lip of the seal.
23. Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the left side 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 five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue.
24. After assembly, wait at least 30 minutes before filling the engine with oil.
25. Clean and dry the oil pump mating surfaces.
26. Install the oil pump (A).
-1 Install a new crankshaft oil seal in the oil pump.
-2 Apply liquid gasket, part No. 08718-0001 or 08718-0003, evenly to the block mating surface of the oil pump and to the inner threads of the bolt holes.
-3 Grease the lip of the oil seal and apply oil to the new O-ring (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.
27. Install the baffle plate (D), then install the oil screen (E).
28. Clean and dry the oil pan mating surfaces.
29. Apply liquid gasket, part No. 08718-000 or 08718-0003 evenly to the oil pan mating surface of the block and to the inner threads of the bolt holes.
30. Install the oil pan with a new gasket.
Oil Pan Bolts:
31. Tighten the bolts in two or three steps. In the final step, tighten all bolts, in sequence, to 12 Nm (1.2 kgf.m, 8.7 ft. lbs.).