Crankshaft Installation

Crankshaft Installation

Special Tools Required

- Driver Handle, 15 x 135L 07749-0010000
- Bearing Driver Attachment, 24 x 26 mm 07746-0010700
- Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

1. Install the crankshaft end bushing when replacing the crankshaft.

Using the driver handle, 15 x 135L and the attachment, 24 x 26 mm drive in the new crankshaft end bushing until the driver handle and the attachment bottom against the crankshaft.





2. Check the main bearing clearance with plastigage Service and Repair.

3. Check the connecting rod bearing clearance with plastigage Service and Repair.

4. Install the bearing halves in the engine block and the connecting rods.

5. Apply a coat of new engine oil to the main bearings and the rod bearings.

6. Hold the crankshaft so rod journal No. 2 and rod journal No. 3 are straight up, then lower the crankshaft into the engine block. Be careful not to damage the journals

7. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block.





8. Inspect the connecting rod bolts Connecting Rod Bolt Inspection.

9. Apply new 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 the cap, then install the caps and the 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 the cap, then install the caps and the bolts finger-tight.

12. Torque the connecting rod bolts to 29 Nm (3.0 kg-m, 22 lb-ft).

13. Tighten the connecting rod bolts an additional 90 °.

NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 8 of the procedure. Do not loosen it back to the specified angle.





14. Remove all of the old liquid gasket from the lower block mating surfaces, the bolts, and the bolt holes.

15. Clean and dry the lower block mating surfaces.

16. Apply liquid gasket, P/N 08717-0004, 08718-0003, or 08718-0009 to the engine block mating surface of the lower block, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





17. Put the lower block on the engine block.

18. Apply new engine oil to the threads of the bearing cap bolts.

19. Torque the bearing cap bolts, in sequence, to 29 Nm (3.0 kg-m, 22 lb-ft).






20. Tighten the bearing cap bolts an additional 56 °.






21. Torque the 8 mm bolts, in sequence, to 22 Nm (2.2 kg-m, 16 lb-ft).

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 lower block.





22. Apply a light coat of new engine oil to the crankshaft and the lip of the crankshaft oil seal.

23. Use the driver handle and the oil seal driver attachment, 96 mm to drive a new oil seal (A) squarely into the engine block to the specified installed height.





24. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.

25. Measure the distance between the engine block (A) and the crankshaft oil seal (B).










26. Install the baffle plates.






27. Install the oil pump.

28. Install the oil pan Engine Oil Pan Installation.

29. Install the cylinder head Cylinder Head Installation.

30. Install the flywheel, the clutch disc, and the pressure plate.

31. Install the transmission Manual Transmission Installation (6MT).

32. Install the engine/transmission assembly Engine Installation.

NOTE: Whenever 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.