Crankshaft and Piston Installation
Crankshaft and Piston Installation
Special Tools Required
- Driver handle 07749-0010000
- Driver attachment, 106 mm 070AD-RCA0200
1. Check the connecting rod bearing clearance with plastigage. Connecting Rod Bearing Replacement
2. Check the main bearing clearance with plastigage. Crankshaft Main Bearing Replacement
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 rod bearings.
5. Lower the crankshaft (A) into the engine block, being careful not to damage the journals and the CKP pulse plate.
6. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 3 journal.
7. Install the bearings (A) and the bearing caps (B) with the arrow (C) facing the timing belt end of the engine block.
8. 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).
9. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in.
10. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore.
11. Attach the ring compressor to the piston/connecting rod assembly, and check that the bearing is securely in place.
12. Position the piston/connecting rod assembly with the arrow (A) facing the timing belt side of the engine.
13. 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.
14. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
15. Measure the diameter of each connecting rod bolt at point A and point B.
16. Calculate the difference in diameter between point A and point B.
Point A-Point B = Difference in Diameter
Difference in Diameter
17. If the difference in diameter is out of tolerance, replace the connecting rod bolt.
18. Line up the mark (A) on the connecting rod and the cap, then install the cap.
19. Apply new engine oil to the bolt threads and flanges. Tighten the bolts (B) to 20 N-m (2.0 kgf-m, 15 lbf-ft).
20. Mark the connecting rod (A) and the bolt head (B) as shown.
21. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 90 °).
NOTE:
- Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 15 of the procedure. Do not loosen it back to the specified angle.
- Repeat step 9 to 21 for the remaining cylinders.
22. Tighten the bearing cap bolts, and then the 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, bolts, and the bolt holes.
24. Clean and dry the engine block end cover mating surfaces.
25. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
26. Drive the new crankshaft oil seal until the driver attachment bottoms on the engine block end cover.
27. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 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 liquid gasket about 2.5 mm (0.098 in.) diameter bead 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 grease off the crankshaft, and check the seal for distortion.
30. Install a new crankshaft oil seal in the oil pump. Service and Repair
31. Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.
32. Clean and dry the oil pump mating surfaces.
33. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 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 liquid gasket about 2.5 mm (0.098 in.) diameter bead 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.
34. Grease the lip of the oil seal, and apply new engine oil 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).
36. Clean the excess grease off the crankshaft, and check the seal for distortion.
37. Install the baffle plate (D), then install the oil screen (E) with a 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.
41. Install the timing belt stopper/crankshaft position (CKP) sensor.
42. Install the cylinder heads. Cylinder Head Installation
43. Install drive plate. Service and Repair
44. Install the transmission. Automatic Transmission Installation
45. Install the engine/transmission. Engine Installation
NOTE: When any crankshaft or connecting rod bearing is replaced, run the engine at idle until it reaches normal operating temperature, then continue to run it for about 15 minutes.
