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 timing 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. Apply engine oil to the threads of the connecting rod bolts.
8. Install the rod caps with bearings, then tighten the connecting rod bolts is sequence to 25 Nm (2.5 kgf-m, 18 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 timing 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.
Crankshaft Installation
Special Tools Required
- Driver 07749-0010000
- Driver attachment 07948-SB00101
1. Check the connecting rod bearing clearance with plastigage.
2. Check the main bearing clearance with plastigage.
3. Apply engine oil to the main bearings and rod bearings.
4. Install the bearing halves in the cylinder block and connecting rods.
5. Hold the crankshaft so rod journal No.2 and rod journal No. 3 are straight up, and lower the crankshaft into the block.
6. Install the thrust washers (A) on both edges of the No. 4 main bearing recess.
7. Apply engine oil to the threads of the connecting rod bolts.
8. Seat the rod journals into connecting rod No.1 and connecting rod No. 4. Install the connecting rod caps and bolts finger-tight. Install the caps so the bearing recess is on the same side as the recess in the rod.
9. Rotate the crankshaft clockwise, and seat the journals into connecting rod No.2 and connecting rod No. 3. Install the connecting rod caps and bolts finger-tight.
10. Tighten the connecting rod bolts in sequence to 25 Nm (2.5 kgf-m, 18 ft. lbs.).
11. Tighten the connecting rod bolts an additional 90°.
12. Apply liquid gasket, part No. 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.
13. Put the lower block on the cylinder block.
14. Tighten the bearing cap bolts is sequence to 29 Nm (3.0 kgf-m, 22 ft. lbs.)
15. Tighten the bearing cap bolts an additional 60°.
16. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf-m, 16 ft. lbs.)
17. Use the special tools to drive a new oil seal squarely into the block to the specified installed height.
18. Measure the distance between the crankshaft (A) and oil seal (B).
19. Install the oil pump (see step 11).
20. Install the cam chain.