Engine Block Special Tools Piston Rings Illustrated Index .. Replacement seer 14 Flywheel and Drive Plate End Gap . .7-14 Replacement Ring-To-Groove Clearance .. 7-15 Main Bearings Alignment . 715 Clearance Piston Pins Selection ... Removal ....ccseccsseee 7-16 Connecting Rod Bearings Installation (B18A1 engine) ........ 7-17 Clearance Installation (B17A1 engine) 7-17 Selection Inspection . 718 Crankshaft Connecting Rods Removal .... End Play .. 7-19 End Play Selection . 7-19 Inspection .. Seal Installation .. Installation Cylinder Block Installation Inspection .. {engine removal not Bore Honing Pistons Inspection .. ssseeee T22, quired) ... 7-22 712 7-13 Installation ..~~ Description @@O890) ISSO@Q® ‘07GAF—PH60300 (O7HAF—PL20102 ‘07LAD—PRAO10A ‘O7LAF—PR30100 (07LAB—PV00100 ‘or 07924PD20003 or 07924—PD20002 '07948-SB00101 077490010000 (07973—PE00310 (07973—-Pe00320 07973~ 6570500 079736570600 Piston Pin Base Insert Piston Base Head Seal Driver Pilot Coll Ring Gear Holder Driver Attachment, Dri Piston Pin Driver Shaft Piston Pin Driver Head Piston Base Piston Base Spring 722 7-22 7-16, 17 7.16, 17 7.16, 17 7.16, 17Illustrated Index Lubricate all internal parts with engine oil during reassembly. NoTE: © Apply liquid gasket to the mating surfaces of the 6x1.0mm right side cover and oil pump case before installing 12 Nim (1.2 kgs, 9 Ib) them. 1 Use liquid gasket, Part No. 08718~0001. on PAN WASHER DRAIN PLUG. Replace. 45 Nem (8.5 ko-m, 6x1.0mm 33 Ibe AY Nem (1-1 kgm, 8 Ib) asker: Replace. = 6x1.0mm 11 Nem (1-tkg-m Bet) 12x1.0mm 108 N-m (10.6 kg-m, 76 tb-f) Torque sequence, page 7-5 ttatemm 73Ns (7.84g-m, 58 bf) ‘Apply engine ol to the bot ‘threads and tho washor. NOTE: Aer torquing leech cap, tum erankshatt {0 check for binding (CRANKSHAFT End play, page 7-9 Runout, Outof-Round, page 7-10 lation, page 7-20, FLYWHEEL (MIT) 12x1.0mm 75 Nem (7.5 kgm, 84 Ibe) Torque seavence, pane 7-5 DRIVE PLATE (A/T) Check for cracks. (B1BAI engine oniy) ‘Apply Equid gasket 10 block mating surece. gip.ny CRANK SEAL Installation, page 7-22: ‘rank and block identification ‘markings. ow Jer Inspection, 8-7 (BT7AT engine ony) on PUMP / Overnaul page 8-8 RIGHT SIDE COVER ‘THRUST WASHERS Grooved sides face outward. NOTE: Thrust washer thickness is fired and must not be changed Dy arinding or shimming 8x4.25 mm 26 Nem (2.4 kgm 17 by ‘CRANK SEAL Installation, page 8-10 on ser Bot 16 Nem (1.6 kg-m, 12 bo-t) Be careful not to damage. 6 ‘Apply quid gasket 4. to block mating (cont'd) surteceIllustrated Index (cont'd) NOTE: New rod bearings must be selected by matching (page 7-7). PISTON RINGS placement, page 7-14 urement, pages 7-14 and 15 Alignment, page 7-15 PISTON INSTALLATION DIRECTION EXHAUST. Removal, page 7.9 Moasucement, page 7-12 Inspect top of each oylinder bore {or carbon builé-up oF ridge before removing piston CONNECTING ROD: Remove ridge if necessary, page 7-8 End play, page 7-19 Selection, page 7-19 Small end meesurement, page 7-18 CONNECTING ROD BEARINGS. Clearance, page 7-7 Seloction, pege 7-7 CONNECTING ROD BEARING CAP Instabaton, page 7-20 NOTE: Install cape so the bearing recess is con tho some side as tho recess in the rod. CONNECTING ROD NUT 8x0.75 mm 32 Nem (3.2 kg-m, 23 b-f) ‘After torquing each bearing, ap, rotate crankshaft t0 for binding. ~ connecting’ tod~and~crenkshatt identification -markings~-——— 74 CPR.Flywheel and Drive Plate r- Replacement Manual Transmission: bolts in the sequence shown. RING GEAR HOLDER ‘07LAB-PV00100, (07924—PD20003 or (07924 —PD20002 ENGINE Lock 07La8—Pv00100, (07924—PD20003 or (07924—PD20002 RING GEAR Inepect ring gear teeth for wear or damage 12x1.0mm 108 N-m (10.5 kgm, 76 b-F) Automatic Transmission: Remove the plate from ht drive plate bolts, then separate the drive Crankshaft flange. After installation, tighten the bolts in the sequence shown. Y2 x 1.0 mim 75 em (7.5 kgm, 54 bi) a De aris. aMain Bearings : Clearance (- Selection check main bearing-to-i CAUTION: If the codes are indecipherable because of move the main cops and bearing halves, ~~ | an accumulation of dirt and-dust,-do-not scrub them with ~ 2. Clean each main journal and bearing half with ¢ josie baw cr ler \cizat eet oly orth wating ll clean shop towel. eed 3. Place one strip of plastigage across each main journal. Crankshaft Bore Code Location (Letters) NOTE: If the engine is still in the car when you bolt the miain cap down to check clearance, the Letters have been stemped on the end of the block as @ weight of the crankshaft and flywheel wil flatten the ‘code for the size of each of the 5 main journal bores. plastigage further than just the torque on the cap Use them, and the numbers or bars stamped on the bolt, and give you an incorrect reading. For an ac- ccrank (codes for main journal size), to choose the cor- ‘curate reading, support the crank with a jack under rect bearings. the counterweights and check only one bearing at one a time. (No.1 JOURNAL) 4, Reinstall the bearings and caps, then torque the bolts to 78 N-m (7.8 kg-m, 56 Ib-ft)(page 7-20). NOTE: Do not rotate the crankshaft during in- spection. 5. Remove the cap and bearings at widest part of the plastigage. Main Bearing-to-Journal Oil Clearance: Standard (New): No. 1, 2,4, 6: 0.024—0.042 mm (0.0008—-0.0017 in} Service Limit: 0.050 mm (0.0020 in) No. 3: 0.030—0.048 mm (0.0012—0.0019 in} Service Limit: 0.060 mm (0.0024 in) PLASTIGAGE STRIP FLYWHEEL END- (NO. JOURNAL) and measure the 6. If the plastigage measures too wide or too narrow, (remove the engine if it’s still in the car), remove the crankshaft, and remove the upper half of the bearing. instal a new, complete bearing with the same color code (select the color as shown in the Booting Identification tight column), and recheck the clearance. Coier cose fon the edge of + arose re CAUTION: Do not file, shim, or scrape the aera a . © >| boarings or the caps to adjust claarance. sate ening eta 7. If the plastigage shows the clearance is still 1 a incorrect, try the next lager of smaller bearing (the [rot | feed [Pk _| votow | Sven Color Hsted above or below that one), and check Zora] | [ont | vetow [icon | town ain Born) | [veow [Gwen [sown | ancx NOTE: If the proper clearance cannot be obtained 4 orm} [Green| frown | eck | tte by using the appropriate larger or smaller bearings, ‘rater Smtr replace the crankshaft and start over. mon bean puns tenckonConnecting Rod Bearings [- Clearance r- Selection 1, Remove the connecting rod cep and beari halt, CAUTION: If the codes are indecipherable because of ‘an accumulation of dirt and dust, do not scrub them with 2. Clean the crankshaft rod journal and bearing half ‘a wire brush or driver. Clean them only with washing oll with a clean shop tow or detergent. 3. Place the plastigage across the rod journal Connecting Rod Code Location (Numbers) 4. Reinstall the bearing half and cap, and torque the nuts to 32 Nem (3.2 kg-m, 23 Ib-tt) (page 7-20) Number has been stamped on the side of each connecting rod as a code for the siza of the big end. Use it, and the letters stamped on the crank (codes for rod journal size), to NOTE: Do not rotate the crankshaft during in- choose the correct bearings. spection. Connecting Rod Bo B18A1 engine: ‘Standard (New): 0.020—0.038 mm {0.0008—0.0015 in) 0.050 mm (0.0020 in) to-Journal Oil Cl Half of number is ‘stamped on bearing 3p and the other half is stamped on ro. Service Limi B17A1 engine: Standard (New): 0.032—0.050 mm (0.0013—-0.0020 in) Service Limits: 0.060 mm (0.0024 in} PLASTIGAGE STRIP 6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color code (select the color as shown in the right column}, and recheck Bearing Identification the clearance. Color code is ‘on the edge of = > Larger big end bore CAUTION: Do not file, shim, or scrape the bearing the bearing. fr the caps to adjust clearance. sina tnaring co 7. If the planigage shows the clearance ie stil incorrect, try the next larger or smaller bearing (the [Ac ! [Red Pik Netow _| Green color listed above or below that one), and check [Boral Pink Yellow | Green| frown josrence eoan 2 clearance 9g [eeril| [vem [Gwen [Bone [aon NOTE: the proper clesrance cannot be obtained [rnd] [om [em [cr "| ue by using the appropriate larger or smaller bearings, replace the crankshaft and start over. mater Smater Jour (Ooexer‘Crankshaft. Removal NOTE!_End play for the'connécting rods and crankshaft sh \spected before removing the crankshaft“, ~ 1. Remove the right side cover 2... Remove the oil sereen: Remove the oil purtip. Remove the baffle ‘plate, ‘Turn the crankshaft so No.2 and 3 crankpins are at the bottom. s . - Remove the rod-caps/beatings and main caps/bear- ings. Keep all capsibeatings in order. Lift the crankshaft out of the engine, being careful not to damage journals. “CRANKSHAFT Remove thé upper bearing halves from connecting ‘ods and set them aside with their respective caps. Reinstall main: caps and bearings on the engine in proper order: If you can feel a ridge of metal or hard carbon around. the top of each cylinder, remove it with a ridge reamer, Folow the reamer manisfacturer's instructions. CAUTION: If the tidge is not removed. it may __ damage the pistons as they aro pushed out. RIDGE REAMER.11. Use the wooden handle of a hammer to drive the pistons out. CAUTION: © Take care not to damage the contact surface of the metal gasket. ‘© When removing the piston/connecting rod, take ‘care not to hit the oil jet (817A1 engine only). © If the oil jet nozzle is damaged or bent, replace the oil jet assembly (B17A1 engine only, page an. HAMMER HANDLE 12. Reinstall the rod bearings and caps after removing ‘each piston/connecting rod assembly. 13. Mark each piston/connecting rod assembly with its eylinder number to avoid mup on reassembly. NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size. -- End Play NOTE: End play should be inspected before removing crankshaft. Push the crank firmly away from the dial indicator, and zero the dial against the end of the crank. Then poll the crank firmly back toward the indicator; dial reading should not exceed service limit. ‘SCREWDRIVER Crankshaft End Play: Standard (New): 0.10—0.35 mm (0.04—0.014 in) Service Limit: 0,45 mm {0.018 in) © If end play is excessive, inspect the thrust washers and thrust surface on the crankshaft. Replace parts 2s necessary. NOTE: ‘© Thrust washer thickness is fixed and must not be changed either by grinding or shimming. © Thrust washers are installed with grooved sides facing outward.- Crarikshaft 8 Rtas — Inspection | noes 22 FAO © Clean the crankshaft oll passages’ wit cleaners of suitable brush. * © Check the keyway end threads. h pipe Alignment 3.0 ; \. @ Measure. runout on all main’ jourials to” make sure the, crank isnot bent: © ‘The difference between measurements on each journal must not.be more than the service limit. Crankshaft Total Indicated Runout: B18A1 engi . Standard (New): 0.03 mm (0.001 in) max. 0.05 mm (0.002 in) Standard (New): 0.020 mm.(0.0008 in) max. Service Limits: 0.030 mm (0.0012 in) DIAL INDICATOR © (Rote two complete revolutions ‘Support with lathe tbe tool or V-blocks Oist-of-Round_and Taper. ‘© Measure out-of-round at the middle of each rod and rain journal in two places. © The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round: B1BA1 engine: ‘Standard (New: 0.005 mm (0.0002 in) max. ‘Service Limit: ~ 0.010 mm (0.0004 in) BI7A1 engine: ‘Standard (New): 0.004 mm (0.00016 in) max. Service Limit: 0.006 mm (0.00024 in) Measure in two places at middle. meoreoses tO FF (@.Measure taper at the edges of each rod and main journal, © The difference between measurements on each journal must not be more than the service limit. Journal Taper: Standard (New): 0.005:mm (0.0002 in) max. Service Limit: 0.010 mm (0.0004 in) BI7A1 engine: Standard (New): 01005 mm (0.0002 in) max. Service Limit: —. _ Ble aeCylinder Block r Inspection 1. Measure wear and taper in direction X and Y at three 2. Check the top of the block for warpage. levels in each cylinder as shown. Measure along the edges and across the center as shown. S Smmio2inn SURFACES TO BE MEASURED G fcoaroment ‘Second Measurement Third Measurement B1BA1 engine: Standard (New): below 0.07 mm (0.003 in} Service Limit: 0.10 mm (0.004 in) BI7A1 engi Standard (New): below 0.05 mm (0.002 in) Service Limit: 0.08 mm (0.003 in) PRECISION STRAIGHT EDGE Cylinder Bore Si ‘Standard (New): X: 81.000~81.020 mm (3.1890—3.1898 in) Y: 81.000-81.015 mm (3.1890—3.1896 in) Service Limit: 81.07 (3.192 in) Oversize: 0,25: 81.250-—81,270 mm (3.1988—3.1996 in) Bore Taper: Service Limit: (Difference between first and third measurement) 0.05 mm (0.002 in) © If measurements in any cylinder are beyond Over- ‘size Bore Service Limit, replace the block. © Ifthe block is to be rebored, refer to Piston Clear- ance Inspection (page 7-12) after reboring. NOTE: Scored or scratched cylinder bores must be honed. Reboring Limit: 0.25 mm (0.01 in)Cylinder Block Pistons - Bore Honing Inspection 8 linger bores 9s shown on page 7-11. 1. Check the piston for distortion or cracks. ithe block fo be reused, hone the eyigers and” | [>= Se n for Seton of ee a ‘remeasure the bores. NOTE: If the cylinder is bored, an oversized piston must be used. 2. Hone cylinder bores with honing ol and a fine (400 ores bn. 60 degree cross-hatch pattem. 2. Measure the piston diameter at a point 15 mm (0.6 in) from the bottom of the skirt. © Use only a rigid hone with 400 grit or finer stone such as Sunnen, Ammco, or equivalent. © Do not use stones that are worn or broken. iston Diameter: ‘Standard (New): 80.980—80.990 mm (3.1882—3.1886 in) ‘Sewvice Limit: 80.970 mm (3.1878 in) skier, ~ diameTeR 7 3. When honingis complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil immediately to prevent rusting NOTE: Never use solvent, it will only redistribute the rit on the oylinder walls. 4. scoring or scratches are stil present in cylinder bores after honing to the service limit, rebore the engine block NOTE: Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the-full length of the bore. ENGINE BLOCK CYLINDER HONE K any \ Note: © After honing, clean the cylinder thoroughly with soapy water. © Only scored or scratched cylinder bores must be honed 7-123. Calculate the difference between cylinder bore diame- ter on (page 7-11) and piston diameter. Piston-to-Cylinder Clearanc Standard (New): 0.010-0.035 mm (0.0004—0.0014 in) Sorvice Limit: 0,05 mm(0.002 in) —--~ 0.08 mm (0.002 in) If the clearance is near or exceeds the service limit, Inspect the piston and cylinder block for excessive Oversize Piston Diameter: 0.26: 81.23—81.24 mm (3.1980—3.1984 in) r- Installation Before installing the piston, apply 2 coat of 7B encine ci 10 the ring grooves and cylinder bores. If the crankshaft is already installed: (© Remove the connecting rod caps and slip short sections of rubber hose over the threaded ends of the connecting rod bolts. © Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder and tap it in using the wood- fen handle of a hammer. Stop after the ring compressor pops fr check the connecting rod-to-crank jour alignment before tapping piston into place. © Install the rod caps with bearings, then torque the nuts to 32 Nem(3.2 kg-m, 23 Ib-f), If the crankshaft is not installed: © Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer. © Position all pistons at top dead center. ‘and 1 ‘CONNECTING ROD The arrow must face OIL HOLE (BIBAT engine) the timing belt side of the engine. The ‘connecting red oil hole ‘must face the intake manifold (B18A1 engine). NOTE: Maintain downward force on the ring Compressor to prevent rings from expanding before entering the cylinder bore. ‘Use the wooden handle of a hammer to push, oF {ap the piston into the ovlinder bore RING COMPRESSORPiston Rings ,- Replacement sxpander, remove old 2. Clean all ring grooves thoroughly. Note: © Use 2 squared-off broken ring or ring groove leaner with blade to fit piston grooves. © Top ring groove is 1.0 mm wide, second groove is 1.2 mm wide, and oll ring groove is 2.8 mm wide © File down blade if necessary. CAUTION: Do not use @ wire brush to clean the ring lands, or cut ring lands deeper with cleaning tool. NOTE: If the piston is to be separated from the con- necting rod, do not install new rings yet. 3. _Install new rings in the proper sequence and position (page 7-15}. NOTE: Do not use old piston rings. PISTON RING RING EXPANDER -- End Gap Using a piston. push @ new ring into the cylinder “bore 15=20-mm-(0:60-8 in}-from’therbottom=—— 2. Measure the ‘piston ring end-gap with a feeler gauge: © the gap is too small, check to see if you have the proper rings for your engine. © If the gap is too large, recheck the cylinder bore diameter against the wear limits on page 7-11 Uf the bore is over the service limit, the engine block must be rebored. Piston Ring End-Gap: Top Ring Standard (New): 0.20—0.30 mm (0.008—0.012 in)" 0.20-0.35 mm (0.008—0.014 in)? Service Limit: 0.60 mm (0.024 in} ‘Second Ring ‘Standard (New): 0.40-0.55 mm (0.016—0.022 in) Service Limit: 0.70 mm (0.028 in} Oit Ring ‘Stendard (New): 0.20—0.45 mm (0.008-0.01 0.20—0.50 mm (0.008 0.020 in)" Service Limit: 0.70 mm (0.028 in) PISTON RING 16-20 mm (0.6-0.8 in} moor *1: TEIKOKU PISTON RING manufactured piston ring +7: RIKEN manufactured piston ring CRS.r Ring-to-Groove Clearance After installing a new set of rings, measure the ring- to-groove clearances: Top Ring Clearance: Standard (New): 0.045—0.070 mm (0.0018—0.0028 in) Service Limit: _ 0.13 mm (0.005 in} ‘Second Ring Clearance: ‘Standard (New): 0.045—0.070 mm (0.0018—0.0028 in)" 0.040-0.065 mm (0.0015—0,0026 in)" Service Limit: 0,13 mm (0.005 in} “+1; TEIKOKU PISTON RING manufactured piston ring “1%: RIKEN manufactured piston ring -~ Alignment 1. Install the rings as shown. Identify top and second rings by the chamfer on the ‘edge. Make sure they are in their proper grooves on the piston, NOTE: The manufacturing marks must be facing CJ ToP RING [A 2. Rotate the rings in their grooves to make sure they do not bind, ' ‘SECOND RING MARK —Y SECOND RING» O1L RING 3. Position the ring end gaps as shown: DO NOT position any ing g6p at piston thrust surfaces. Q \ SECOND RING GAP ‘Approx. 90° on rina Approx 15 GAP i) 7 TOP RING GAP 15\ spacer GAP DO NOT positon any ring gap in ine with the pieton pinhole. OL RING GAPPiston Pins” Removal ———— 1, Assemble. the’ Piston Pin Tools.as shown. PISTON BASE HEAD" ‘O7HAF—PL20102° i : p 49.70 mm (1.987 in) oe 1.70 mm (2.035 in} PISTON PIN DRIVER HEAD. 07973—-PE00320, |___— PISTON PIN DRIVER SHAFT (07973-PE00310 PISTON BASE 079736570500 PILOT COLLAR |» —~ o7taF—PR30100 NOTE: Use = hvdrauic pres. eS ‘When pressing pin in or out, make sure that th recestod ; Porton ofthe piston aligns 7 tvth the ips on the cote ; ‘3, Place the piston on the piston base and press the pin out with a hydraulic press.r- Installation (B18A1 engine) 1. Use @ hydraulic press for installation, ‘© When pressing the pin in or out, be sure to position the recessed flat on the piston against the lugs on the base attachment, ‘The arrow must face the timing belt side of the fengine and the connecting 09 al hole must face tho at side of the engine. CONNECTING ROD. OWL HOLE 2. Adjust the length B of the piston pin driver. B: 49.70 mm (1.957 in} PISTON PIN DRIVER HEAD '07973—PE00320 PISTON PIN ORIVER SHAFT 07973-PE00310 facing up. PILOT COLLAR “Tf o7ar—Pn30100 PISTON PIN BASE INSERT [-—- (07GAF—PH60300 PISTON BASE HEAD O7HAF-PL20102 |__— piston Base (07973-6570500 NOTE: Install the assembled piston and rod with the oil hole facing the intake manifold. - Installation (B17A1 engine) 1. Use a hydraulic press for installation. ‘+ When pressing pin in or out, be sure you posi- tion the recessed flat on the piston against the lugs on the base attachment. ‘The arrow must face the timing belt side of the engine the timing of the engine, 2. Adjust the length 8 of piston pin driver. B: 51.70 mm (2.035 in) PISTON PIN 4 —— DRIVER HEAD 07973-PE00320 " PISTON PIN DRIVER SHAFT (07973~PE00310 {Og tar couan J 147, Grae PRN HM | UU PISTON PIN BASE INSERT |+—~ o7Gar—pHeo300 Embossed mark facing up. |«— PISTON BASE HEAD O7HAF—PL20102 |«— PISTON BASE (079736570600Piston Pins * Inspection diameter of the piston pir Oversize: 20,897—21.003 mm (0:8267—0.8269 in) NOTE: All ‘eplacement piston pins are oversize. Zero the dial indicator to the piston pin diameter. NOTE:' Check the piston for distortion or cracks. If the piston pin clearance is greater than 0.022 ‘mm (0.0009 in}, remeasure using an oversize piston pin. Piston Pin-to-Piston Clearance: Standard (New): 0.010—0.022 mm, (0.0004—0.0009 in) Check the difference between piston pin diameter ‘and connecting rod small end diameter. Piston Pin-to-Connecting Red Interference: Standard (Now): 0.013-0.032 mm (0.0005 0.0013 in)Connecting Rods be] r End Play NOTE: End play should be inspected before removing the crankshaft. Connecting Rod End Play: Standard (Now): 0:15—0.30 mm (0.006-0.012 in) Sorvice Limit: 0.40 mm (0.01 CONNECTING ROD CRANKSHAFT © 1f out-of-tolerance, install a new connecting rod. © If stil outoftolerance, replace the crankshaft (page 7-8 and 7-20) r Selection Each rod falls into one of four tolerance ranges (from 0 to + 0.024 mm, in 0.006 mm increments) depend- ing on the size of its big end bore. I's then stamped with 2 number (1, 2, 3, oF 4) indicating the ran You may find any combination of 1, 2, 3, or 4 in any engine. Normal Bore Size: 48.0 mm (1.89 in) NOTE: © Reference numbers are for big end bore size and do NOT indicate the position of the rod in the engine. © Inspect connecting rod for cracks and heat damage. CONNECTING ROD BORE REFERENCE NUMBER Haif of number is stamped on ‘bearing cap, the other half on connecting tod Inspect bolts ‘and nuts for ‘stress cracksCrankshaft Installation |. Before installing the crankshaft, apply.a coat of ‘engine oil to the main bearings and rod bearings 1. Insert bearing halves in the engine block and con- necting rods. 2. Hold the crankshaft so rod journals for cylinders No, 2 and No. 3 are straight up. 3. Lower the crankshaft into the block, seating the rod journals into connecting rods No.2 and No.3. Install the rod caps and nuts finger tight Not Noa CONNECTING ROD CONNECTING ROD CONNECTING ROD ‘THRUST WASHERS Nos Grooved side facing CONNECTING ROD outward. 4, Rotate the crankshatt clockwise, seat journals into ‘connecting rods No. 1 and No.4, and install the rod caps and nuts finger tight. NOTE: Install caps so the bearing recess is on the same side as the recess in the rod, 5. Check rod bearing clearance with plastigage (page 7-7) then tighten the capnuts in 2 steps. Ast stop: 20 Nem(2.0 kgm, 14 Ib) 2nd step: 82 Nem(3.2 kg-m, 23 tb-ft) NOTE: Reference numbers on connecting rod are for big-end bore tolerance and do NOT indicate the position of piston in the engine. bearing caps. ~" Check “clearance with” plastigage’ (page-7-6); tighten the bearing cap bolts in 2 steps. In the first step tighten al bolts in sequence to about 30 Nem (3.0 kg-m, 22 Ib-ft).in the final step tight- ‘en in same sequence to 78 Nem (7.8 kg-m, 56 Ib-ft. NOTE: Coat the bolt thr 7. Install the baffle plate. 8. Apply non-hardening liquid gasket to the block mating ‘surface of the right side cover and oil pump, and instal them on the engine block. RIGHT SIDE COVER: ‘Apply tguld {gasket to block DOWEL PINS mating surface. 6x1.0mm 11 Nem (1.1 kgm, Bit RIGHT SIDE COVER 6x1.0%mm 11m (1.1 kgm, 8 mA) 7-20o1t pump: on pump: ee 6x 1.0mm OWL SCREEN. 11 Nem (1.1 kg-m, 8 Ibs) 61.0 mm 11 Nem (1.1 kgm, on PUMP tote ‘ply liguid gasket te block mating surface. 18x 1.25 mm 24 Nem (2.4 kgm, Tee) ‘Apply liquid gasket along the broken line. 9. Install the oll screen. 10. Install the oil pan. AD Nem (1-1 kgm, 8 tb-f) Wid gasket, Part No. 08718-0001. © Check that the mating surfaces are clean and dry before applying liquid gasket. © Apply iquid gasket as an even bead, centered be- tween the edges of the mating surface. © To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes, © Do not install the parts if 20 minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue, © After assembly, wait at least 30 minutes before filing the engine with ol RIGHT SIDE Cover: NOTE: Tighten the bolts and nuts in two steps and torque the bolts in a oriss-cross pattern. RIGHT SIDE COVER Appiy liquid gasket slong ‘the broken tine. RRS.Oil Seal Installation [Installation (engine removal not — required) The seal surface on the block should be dry. \ ‘Apply alight coat of oil tothe crankshaft and to ~|~ |= The seal surface on the block should be drys SY ‘the lip of the seal. Apply a light coat of grease to the crankshaft and to the lip of seal 1. Drive in flywheel ond seal against right side cover NOTE: | Drive the end seal in squarely. 1, Using the special tool, drive timing pulley-end pniven seal until the driver bottoms against the ll pump. ‘When the seal is in place, clean any excess grease off (07749-0010000 ‘the crankshaft and check that the:oil seal lip is not distorted SEAL DRIVER ‘ ‘O7LAD—PRAOIOA, natal eal with the part number side facing out 2. Using the special tool, drive in the flywheel-end seal unt the dvr Bottoms against block, DRIVER ATTACHMENT Int sot withthe 07946~s800101 ar amber sie NOTE: Align the hol in the driver attachment with the pin on the cr 2. Confirm that clearance is equal all the way: a feeler gauge. Clearance: 0.5—0.8 mm (0.02—0.03 in) 0.5~0.8 mm: (0.02-0.03 in) RIGHT SIDE COVER FLYWHEEL END ‘SEAL (07948—SB00101 Install sel withthe art number side facing ov. NOTE: Refer to right column and 8-10 for installa tion of the oil pump side oil sea, 7-22