Piston and Crankshaft Installation
Piston InstallationIf the crankshaft is already installed
1. Set the crankshaft to bottom dead center (BDC) for each cylinder.
2. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
3. Position the arrow (A) facing the cam chain side of the engine.
4. 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.
5. Stop after the ring compressor pops free, and check the connecting-rod-to-crank-journal alignment before pushing the piston into place.
6. Check the connecting rod bearing clearance with plastigage.
7. Inspect the connecting rod bolts.
8. Apply engine oil to the bolt threads, then install the rod caps with bearings. Torque the bolts to 20 Nm (2.0 kgf-m, 14 ft. lbs.).
9. Tighten the connecting rod bolts an additional 90°.
If the crankshaft is not installed
1. Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place.
2. Position the arrow (A) facing the cam chain side of the engine.
3. 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.
4. Position all pistons at Top Dead Center (TDC).
Connecting Rod Bolt Inspection
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 the connecting rod bolt.
Crankshaft Installation
Special Tools Required
- Driver 07749-0010000
- Attachment, 24 x 26 mm 07746-0010700
- Oil seal driver attachment 96 07ZAD-PNA0100
1. With a manual transmission, install the crankshaft end bushing when replacing the crankshaft. Using the special tools, drive in the crankshaft end bushing until the special tool bottoms against the crankshaft.
2. Check the connecting rod bearing clearance with plastigage.
3. Check the main bearing clearance with plastigage.
4. Inspect the connecting rod bolts.
5. Install the bearing halves in the cylinder block and connecting rods.
6. Apply a coat of engine oil to the main bearings and rod bearings.
7. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the block.
8. Install the thrust washers (A) in the No. 4 journal of the cylinder block.
9. Apply engine oil to the threads of the connecting rod bolts.
10. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (B) on the connecting rod and cap, then install the caps and bolts finger-tight.
11. Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and cap, then install the caps and bolts finger-tight.
12. Tighten the connecting rod bolts to 20 Nm (2.0 kgf-m, 14 ft. lbs.).
13. Tighten the connecting rod bolts an additional 90°.
14. Remove old liquid gasket from the lower block mating surfaces, bolts, and bolt holes.
15. Clean and dry the lower block mating surfaces.
16. Apply liquid gasket, P/N 08718-0009, evenly to the cylinder block mating surface of the lower block and to the inner threads of the bolt holes.
NOTE: Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing old residue.
17. Put the lower block on the cylinder block.
18. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf-m 22 ft. lbs.)
19. Tighten the bearing cap bolts an additional 56°.
20. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf-m 16 ft. lbs.)
21. Use the special tools to drive a new oil seal squarely into the block to the specified installed height.
22. Measure the distance between the crankshaft (A) and oil seal (B).
23. Install the baffle plates.
24. Install the oil pump.
25. Install the oil pan.
26. Install the cylinder head.
27. Install the transmission:
- Manual transmission.
- Automatic transmission.
28. Install the engine assembly.