Engine Block

Special Tools.......................................................................7-2
Component Location Index.............................................. 7-3
Connecting Rod and Crankshaft End Play Inspection. 7-5
Crankshaft Main Bearing Replacement........................ 7-5

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Connecting Rod Bearing Replacement..........................7-7
Oil Pan Rem oval................................ ................................7-9
Crankshaft and Piston Removal...................................... 7-11
Crankshaft Inspection....................................................... 7-13
Block and Piston Inspection..................... ....................... 7-14
Cylinder Bore Honing....................................................... 7-16
Piston, Pin, and Connecting Rod Replacement............7-16
Piston Ring Replacement................................................. 7-19
Piston Installation............................................................. 7-21
Connecting Rod Bolt Inspection.....................................7-23
Crankshaft Installation........ .............................................7-23
CKP Pulse Plate Replacement......................................... 7-27
Oil Pan Installation............................................................7-28
Transmission End Crankshaft Oil Seal Installation - In
C ar.................................................................................... 7-31
Drain Bolt/Sealing Bolt Installation................................ 7-32
Special Tools

Ref.No. Tool Number Description Qty

070AF-PWC0110 Pilot Pin 1
© 070AF-PWC0120 Insert Adjust 1
© 070AF-PWC0130 Pilot Collar, O.D. 18 mm 1
07749-0010000 Driver Handle, 1 5 x 1 35L 1
© 07946-1870100 Bearing Driver Attachment, 28 x 30 1
© 07973-6570201 Adjustable Piston Pin Driver Head 1
© 07973-6570500 Piston Base 1
© 07973-6570600 Piston Base Spring 1
© 07TGF-001000A Piston Base Head 1
© 07ZAD-PN AA100 Oil Seal Driver Attachment, 96 mm 1

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Component Location Index

PILOT BEARING
(M /T model)
Inspection, page 12-17
Replacement, page 12-17

BEARING CAP BRIDGE

CRANKSHAFT END
BUSHING (A/T model)
Installation, step 2 on page 7-23
DOWEL PINS

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M A IN BEARING CAPS

DOWEL PINS

TRANSMISSION END
CRANKSHAFT OIL SEAL
Installation, step 28 on page 7-26
Install ation - In Car, page 7-31

CRANKSHAFT
End Play, page 7-5
Removal, page 7-11
Inspection, page 7-13
Installation, page 7-23

M A IN BEARINGS
Replacement, page 7-5

SEALING BOLT
Installation, page 7-32 DRAIN BOLT
Instal lation, page 7-32

KNOCK SENSOR SEALING BOLT

Installation, page 7-32
Component Location Index (cont'd)

PISTON RI NGS
Rep l acement, page 7-19

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Inspecti on, page 7-23
 h s

Connecting Rod and Crankshaft Crankshaft Main Bearing

End Play Inspection Replacement
1. Remove the oil pump (see page 8-14). Main Bearing Clearance Inspection
2. Measure the connecting rod end play with a feeler 1. Remove the bearing cap bridge, the main bearing
gauge (A) between the connecting rod (B) and the caps, and main bearing halves (see page 7-11).
crankshaft (C).
2. Clean each main journal and main bearing half with a
Connecting Rod End Play clean shop towel.
Standard (New): 0.15—0.35 mm (0.006—0.013 in)
Service Limit: 0.40 mm (0.015 in) 3. Place one strip of plastigage across each main
journal.
4. Reinstall the main bearings, the main bearing caps,
and the bearing cap bridge, then torque the bearing
cap bolts to 25 N-m (2.5 kgf-m, 18 Ibf-ft) in the proper
sequence.
NOTE:
• Apply new engine oil to the bolt threads and

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flanges.
• Do not rotate the crankshaft during inspection.

3. If the connecting rod end play is beyond the service

limit, install a new connecting rod, and recheck. If it is
still beyond the service limit, replace the crankshaft
(see page 7-11).
4. To check crankshaft end play, push the crankshaft
firmly away from the dial indicator by prying, and zero
the dial against the end of the crankshaft. Then pull
the crankshaft firmly back toward the indicator by
prying; the dial reading should not exceed the service
limit.
Crankshaft End Play
Standard (New): 0.10—0.35 mm (0.0039—0.0138 in)
Service Limit: 0.45 mm (0.0177 in)

5. If the end play is beyond the service limit, replace the

thrust washers, and recheck. If it is still beyond the
service limit, replace the crankshaft (see page 7-11).
Crankshaft Main Bearing Replacement (cont'd)

6. Remove the bearing cap bridge, the main bearing Main Bearing Selection
caps, and the main bearing halves, and measure the
widest part of the plastigage. Block Bore Code Location

Main Bearing-to~Journal Oil Clearance Letters have been stamped on the end of the engine
Standard (New): 0.018—0.036 mm block as a code for the size of each of the five main
(0.00071-0.00142 in) journal bores.
Service Limit: 0.050 mm (0.00197 in)
Use them, and the numbers stamped on the crankshaft
(codes for main journal size), to choose the correct main
bearings. If the codes are indecipherable because of an
accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or
detergent.

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7. If the plastigage measures too wide or too narrow,
remove the crankshaft, and remove the upper half of
the main bearing. Install a new, complete main
bearing with the same color code, and recheck the
clearance. Do not file, shim, or scrape the main
bearings or the main bearing caps to adjust clearance.
8. If the plastigage shows the clearance is still incorrect,
No. 5 JOURNAL No. 1 JOURNAL
try the next larger or smaller main bearing (the color (Transmission end) (Pulley end)
listed above or below that one), and check the
clearance again. If the proper clearance cannot be Bearing
Identification - ► Larger crank bore
obtained by using the appropriate larger or smaller
main bearings, replace the crankshaft (see page 7-11) Color code is on the A B C D
and start over. edge of the bearing
- ► Smaller bearing (Thicker)

W hite Red Pink Yellow

Red Pink Yellow Green

Pink Yellow Green Brown

Yellow Green Brown Black

Smaller Smaller
main bearing
journal (Thicker)
 Connecting Rod Bearing
Replacement
Main Journal Code Location Connecting Rod Bearing Clearance Inspection
1. Remove the bearing cap bridge (see page 7-11).
2. Remove the connecting rod cap and the connecting
rod bearing half.
3. Clean the connecting rod journal and the connecting
rod bearing half with a clean shop towel.
4. Place one strip of plastigage across the connecting
rod journal.
5. Reinstall the connecting rod bearing half and the
connecting rod cap, and torque the connecting rod
bolts to 9.8 N-m (1.0 kgf-m, 7 Ibf-ft) +90 °.
No. 5 JOURNAL No. 1 JOURNAL
(Transmission end) (Pulley end) NOTE:

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• Apply new engine oil to the bolt threads and
flanges.
• Do not rotate the crankshaft during inspection.
Connecting Rod Bearing Replacement (cont'd)

6. Remove the connecting rod cap and the connecting Connecting Rod Bearing Selection
rod bearing half, and measure the widest part of the
plastigage. Each connecting rod falls into one of four tolerance
ranges (from 0 to 0.024 mm (0.00095 in), in 0.006 mm
Connecting Rod Bearing-to-Journal Oil (0.00024 in) increments) depending on the size of its big
Clearance
end bore.
Standard (New): 0.020—0.038 mm
(0.00079-0.00150 in) It's then stamped with a number (1,2, 3, or 4) indicating
Service Limit: 0.050 mm (0.00197 in) the range. You may find any combination of 1, 2, 3, or 4
in any engine.

Big End Bore Size: 43.0 mm (1.693 in)

Inspect each connecting rod for cracks and heat
damage.
Connecting Rod Big End Bore Code Locations

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Numbers have been stamped on the side of each
connecting rod as a code for the size of the big end. Use
them, and the letters stamped on the crank (codes for
rod journal size), to choose the correct connecting rod
bearings. If the codes are indecipherable because of an
accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or
detergent.
7. If the plastigage measures too wide or too narrow,
Ha l f of the number is
remove the upper half of the connecting rod bearing.
Install a new, complete connecting rod bearing with
the same color code, and recheck the clearance. Do
not file, shim, or scrape the connecting rod bearings
or the connecting rod caps to adjust clearance.
8. If the plastigage shows the clearance is still incorrect,
try the next larger or smaller connecting rod bearing
(the color listed above or below that one), and check
the clearance again. If the proper clearance cannot be
obtained by using the appropriate larger or smaller
connecting rod bearings, replace the crankshaft (see
page 7-11) and start over.
 te a

Oil Pan Removal

Bearing 1. If the engine is already out of the vehicle, go to step 7.

Identification - ► Larger big rod bore
2. Drain the engine oil (see page 8-10).
1 2 3 4
Color code is on the
3. Remove the drive belt (see page 4-29).
- ► Smaller bearing (Thicker)
4. Remove the driveshaft heat shield (see step 33 on
A Red Pink Yellow Green page 5-6).
B Pink Yellow Green Brown 5. Remove the A/C compressor without disconnecting
the A/C hoses (see step 37 on page 5-7).
C Yellow Green Brown Black
6. A/T model: Remove the shift cable cover (A).
D Green Brown Black Blue
V
Smaller Smaller
rod bearing
journal (Thicker)

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Connecting Rod Journal Code Location

7. M/T model: Remove the torque rod bracket (see page

No. 4 JOURNAL No. 1 JOURNAL
(Transmission end) (Pulley end) 5-30).
8. Remove the dipstick, then remove the dipstick tube
(A).
Oil Pan Removal (cont'd)

9. Remove the CKP sensor cover (A), then disconnect 10. Remove the clutch case cover/torque converter case
the CKP sensor connector (B). cover (A), and the transmission mounting bolts (B).
M /T model

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A/T model
 Crankshaft and Piston Removal

11. Remove the oil pan bolts. Note the bolt locations by 1. Remove the engine/transmission (see page 5-3).
their size.
2. Remove the transmission.
• M/T model (see page 13-7)
• A/T model (see page 14-193)
3. M/T model: Remove the pressure plate (see page
12-14), the clutch disc (see page 12-15), and the
flywheel (see page 12-16).
4. A/T model: Remove the drive plate (see page 14-200).
5. Remove the CKP sensor cover (A), then disconnect
the CKP sensor connector (B).

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12. Using a flat-blade screwdriver, separate the oil pan
from the block in the places shown.

7. Remove the cylinder head (see page 6-25).

8. Remove the oil pan (see page 7-9).

13. Remove the oil pan.

(cont'd)
Crankshaft and Piston Removal (cont'd)

9. Remove the oil screen (A), then remove the oil pump 13. Lift the crankshaft (A) out of the engine block, being
(B). careful not to damage the journals and the CKP pulse
plate (B).

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10. Remove the bearing cap bolts. To prevent warpage, 14. Remove the CKP pulse plate.
unscrew the bolts in sequence 1/3 turn at a time;
repeat the sequence until all bolts are loosened. 15. Remove the upper connecting rod bearing halves
from the connecting rods, and set them aside with
(D © © their respective caps.
16. If you can feel a ridge of metal or hard carbon around
the top of each cylinder, remove it with a ridge reamer
(A). Follow the reamer manufacturer's instructions. If
the ridge is not removed, it may damage the pistons
as they are pushed out.

11. Remove the bearing cap bridge and the main bearing
caps.
12. Remove the connecting rod caps/bearings. Keep all
connecting rod caps/bearings in order.
 n 9

Crankshaft Inspection

17. Use the wooden handle of a hammer (A) to drive out Out-of-Round and Taper
the piston/connecting rod assembly (B). Take care not
1. Remove the crankshaft from the engine block (see
to damage the cylinder with the connecting rod.
page 7-11).
2. Clean the crankshaft oil passages with pipe cleaners
or a suitable brush.
3. Check the keyway slot and the threaded holes for
damage.
4. Measure the out-of-round at the middle of each
connecting rod and the main journal in two places.
The difference between measurements on each
journal must not be more than the service limit.
Journal Out-of-Round
Standard (New): 0.005 mm (0.00020 in) max.

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Service Limit: 0.010 mm (0.00039 in)

18. Reinstall the main bearings, the main bearing caps,

©
HMVUflo
and the bearing cap bridge on the engine block in the
proper order.
19. Reinstall the connecting rod bearings and the
connecting rod caps after removing each
piston/connecting rod assembly.
20. Mark each piston/connecting rod assembly with its
cylinder number to make sure they are reused in
original order.
i __ I
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it indicates
the rod bore size. 1 f
5. Measure the taper at the edges of each connecting
rod and the main journal. The difference between
measurements on each journal must not be more
than the service limit.
Journal Taper
Standard (New): 0.005 mm (0.00020 in) max.
Service Limit: 0.010 mm (0.00039 in)

(cont'd)
Crankshaft Inspection (cont'd) Block and Piston Inspection

Straightness 1. Remove the crankshaft and the pistons (see page

7-11).
6. Place the V-blocks on a flat surface.
2. Check the piston for distortion or cracks.
7. Check the total runout with the crankshaft supported
on V-blocks. 3. Measure the piston skirt diameter (A) at a point 16 mm
(0.63 in) from the bottom of the skirt.
8. Measure the runout on all of the main journals. Rotate
the crankshaft two complete revolutions. The Piston Diameter
difference between measurements on each main Standard (New): 72.980—72.990 mm
journal must not be more than the service limit. (2.87322-2.87362 in)
Service Limit: 72.97 mm (2.8728 in)
Crankshaft Total Runout
Standard (New): 0.03 mm (0.0012 in) max. Oversize Piston Diameter
0.25: 73.230-73.240 mm (2.88307-2.88346 in)
Service Limit: 0.04 mm (0.0016 in)

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4. Measure wear and taper in direction Y at three levels 6. Check the top of the engine block for warpage.
in each cylinder as shown. If measurements in any Measure along the edges and across the center as
cylinder are beyond the oversize bore service limit, shown.
replace the engine block. If the engine block is to be
Engine Block Warpage
rebored, refer to step 7 after reboring.
Standard (New): 0.07 mm (0.002 in) max.
Cylinder Bore Size
Standard (New): 73.000—73.015 mm
(2.87401-2.87460 in)
Service Limit: 73.065 mm (2.87657 in)
Oversize
0.25: 73.250-73.265 mm (2.88385-2.88444 in)
Reboring limit: 0.25 mm (0.0098 in) max.
Bore Taper
Limit: (Difference between first and third
measurement) 0.05 mm (0.0020 in)

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7. Calculate the difference between the cylinder bore
diameter and the piston diameter. If the clearance is
near or exceeds the service limit, inspect the piston
and engine block for excessive wear.
Piston-to-Cylinder Clearance
Standard (New): 0.010—0.035 mm
(0.00039-0.00138 in)
Service Limit: 0.05 mm (0.0020 in)

SERVICE LIMIT
0.05 mm (0.0020 in)

5. Scored or scratched cylinder bores must be honed

(see page 7-16).
Cylinder Bore Honing Piston, Pin, and Connecting Rod
Replacement
1. Measure the cylinder bores (see page 7-14). Special Tools Required
• Pilot Pin 070AF-PWC0110
If the engine block is to be reused, hone the cylinders
• Piston Base 07973-6570500
and remeasure the bores. Only scored or scratched
• Piston Base Spring 07973-6570600
cylinder bore must be honed.
• Piston Base Head 07TGF-001000A
2. Hone the cylinder bores with honing oil and a fine • Pilot Collar, O.D. 18 mm 070AF-PWC0130
(400 grit) stone in a 60 degree cross-hatch pattern (A). • Insert Adjust 070AF-PWC0120
• Adjustable Piston Pin Driver Head 07973-6570201
NOTE:
• Use only a rigid hone with 400 grit or finer stone Disassembly
such as Sunnen, Ammco, or equivalent.
1. Remove the piston from the engine block (see page
• Do not use stones that are worn or broken.
7-11).
2. Assemble the special tool as shown.

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3. When honing is complete, thorough^ ,.ean the
engine block of all metal particles. Wash the cylinder
bores with hot soapy water, then dry and oil them
immediately to prevent rusting.
NOTE: Never use solvent, it will only redistribute the
grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder
bores after honing to the service limit, re bo re the
engine block. Some light vertical scoring and
scratching is acceptable if it is not deep enough to 3. Temporarily install the pilot collar, O.D. 18 mm (A)
catch your fingernail and does not run the full length over the pilot pin (B), and adjust the piston base head
of the bore. (C) as shown, then tighten the screws (D). Remove the
pilot collar.
4. Assemble and adjust the length of the adjustable Inspection
piston pin driver head (A) and insert adjust (B) to 45
mm (1.77 in). NOTE: Inspect the piston, the piston pin, and the
connecting rod when they are at room temperature.
45 mm (1.77 in)
1. Measure the diameter of the piston pin.
Piston Pin Diameter
Standard (New): 17.996—18.000 mm
(0.70850-0.70866 in)

07973-6570201 070AF-PWC0120
5. With the arrow on top of the piston pointing up, place
the piston/connecting rod assembly (A) on the piston

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base head (B).
Be sure you position the recessed flat area of the
piston against the area of the piston base head (C) as
shown.

6. Press the piston pin (D) out with the adjustable piston
pin driver head and insert adjust (E), the pilot collar
(F), and a hydraulic press.

(cont'd)
Piston, Pin, and Connecting Rod Replacement (cont'd)

3. Check the difference between the piston pin diameter Reassembly

and the piston pin hole diameter in the piston.
1. Assemble the piston and the connecting rod with the
Piston Pin-to-Piston Clearance arrow (A) and the embossed mark (B) on the same
Standard (New): 0.010—0.017 mm
side.
(0.00039-0.00067 in)

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2. Insert the pilot collar (A) into the piston and the
connecting rod.
4. Check the difference between the piston pin diameter
and connecting rod small end diameter.
Piston Pin-to-Connecting Rod
Interference
Standard (New): 0.019—0.036 mm
(0.00075-0.00142 in)

3. With the arrow on top of the piston and the embossed

mark on the connecting rod facing up, place the
piston/connecting rod assembly (B) on the piston
base head (C). Be sure you position the recessed flat
area of the piston against the area of the piston base
head (D) as shown.
4. Press the piston pin (E) in with the adjustable piston
pin driver head and insert adjust (F) and a hydraulic
press.
Piston Ring Replacement

1. Remove the piston from the engine block (see page 4. Using a piston, push a new ring (A) into the cylinder
7-11). bore 15—20 mm (0.59—0.79 in) from the bottom.
2. Using a ring expander (A), remove the old piston
rings (B).

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1 5 -2 0 mm (0.59-0.79 in)

5. Measure the piston ring end-gap (B) with a feeler

gauge:
• If the gap is too small, check to see if you have the
3. Clean all the ring grooves thoroughly with a
squared-off broken ring, or a ring groove cleaner with proper rings for your engine.
a blade to fit the piston grooves. File down the blade, • If the gap is too large, recheck the cylinder bore
if necessary. The top and second ring grooves are diameter against the wear limits (see page 7-14).
1.0 mm (0.039 in) wide, and the oil ring groove is If the bore is over the service limit, the engine block
2.0 mm (0.079 in) wide. Do not use a wire brush to must be rebored.
clean the ring grooves, or cut the ring grooves deeper Piston Ring End-Gap
with the cleaning tool. Top Ring:
NOTE: If the piston is to be separated from the Standard (New): 0.15—0.30 mm (0.006—0.011 in)
connecting rod, do not install new rings yet. Service Limit: 0.60 mm (0.023 in)
Second Ring:
RIKEN
Standard (New): 0.30-0.42 mm (0.012-0.016 in)
Service Limit: 0.65 mm (0.025 in)
NIPPON
Standard (New): 0.35—0.50 mm (0.014—0.019 in)
Service Limit: 0.65 mm (0.025 in)
Oil Ring:
Standard (New): 0.20—0.70 mm (0.008—0.027 in)
Service Limit: 0.80 mm (0.031 in)
Piston Ring Replacement (cont'd)

6. Install the rings as shown. The top ring (A) has a R or 7. After installing a new set of rings, measure the
1N mark, and the second ring (B) has a 2R or 2N mark. ring-to-groove clearances.
The manufacturing marks (C) must be facing upward.
Top Ring-to-groove Clearance
RIKEN
Standard (New): 0.065—0.090 mm (0.003—0.003 in)
Service Limit: 0.15 mm (0.005 in)
NIPPON
Standard (New): 0.061 —0.090 mm (0.003—0.003 in)
Service Limit: 0.15 mm (0.005 in)
Second Ring-to-groove Clearance
Standard (New): 0.030-0.055 mm (0.002-0.002 in)
Service Limit: 0.12 mm (0.004 in)

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8. Rotate the rings in their grooves to make sure they do
not bind.
9. Position the ring end gaps as shown:

About 90 °
Piston Installation

If the Crankshaft is Already Installed 5. Position the piston/connecting rod assembly in the
cylinder, and tap it in using the wooden handle of a
1. Set the crankshaft to bottom dead center (BDC) for hammer (A).
each cylinder as its piston is installed. Maintain downward force on the ring compressor (B)
to prevent the rings from expanding before entering
2. Remove the connecting rod caps, and check that the
the cylinder bore.
connecting rod bearing is securely in place.
3. Apply new engine oil to the piston, inside of the ring
compressor, and the cylinder bore, then attach the
ring compressor to the piston/connecting rod
assembly.
4. Position the piston/connecting rod assembly with the
arrow (A) facing the cam chain side of the engine
block.

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6. Stop after the ring compressor pops free, and check
the connecting rod-to-connecting rod journal
alignment before pushing the piston into place.
7. Check the connecting rod bearing clearance with a
plastigage (see page 7-7).
8. Inspect the connecting rod bolts (see page 7-23).
9. Apply new engine oil to the bolt threads and flanges,
then install the connecting rod caps with connecting
rod bearings. Torque the bolts to 9.8 N-m (1.0 kgf-m,
7 Ibf-ft).

(cont'd)
Piston Installation (cont'd)

10. Tighten the connecting rod bolts an additional 90 °. If the Crankshaft is Not Installed
NOTE: Remove the connecting rod bolt if you 1. Remove the connecting rod caps, and check that the
tightened it beyond the specified angle, and go back connecting rod bearing is securely in place.
to step 8 of the procedure. Do not loosen it back to the
specified angle. 2. Apply new engine oil to the piston, inside of the ring
compressor, and the cylinder bore, then attach the
ring compressor to the piston/connecting rod
assembly.
3. Position the piston/connecting rod assembly with the
arrow (A) facing the cam chain side of the engine
block.

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4. 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.

5. Position all pistons at top dead center (TDC).

 k g

Connecting Rod Bolt Inspection Crankshaft Installation

1. Measure the diameter of each connecting rod bolt at Special Tools Required
point A and point B with a micrometer. • Bearing Driver Attachment, 28 x 30 mm 07946-1870100
. Driver Handle, 15 x 135L 07749-0010000
30 mm (1.18 in) • Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

1. M/T model: Install the pilot bearing when replacing

the crankshaft (see step 23 on page 12-17).
2. A/T model: Install the crankshaft end bushing when
replacing the crankshaft. Using the driver handle, 15 x
135L (A) and the bearing driver attachment, 28 x 30
mm (B), to drive the crankshaft end bushing squarely
into the crankshaft to the specified installed height.

15 m m (0.59 in)

2. Calculate the difference in diameter between point A

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and point B.
Point A —Point B = Difference in Diameter
Difference in Diameter
Specification: 0 —0.05 mm (0—0.0020 in)
3. If the difference in diameter is out of tolerance,
replace the connecting rod bolt.

3. A/T model: Measure the distance between the

crankshaft (A) surface and crankshaft end bushing (B).
Bushing Installed Height
0.9-1.1 mm (0.035-0.043 in)

(cont'd)
Crankshaft Installation (cont'd)

4. Check the main bearing clearance with a plastigage 10. Apply new engine oil to the side with the thrust
(see page 7-5). washer groove. Install the thrust washers (A) in the
No. 4 journal.
5. Check the connecting rod bearing clearance with a
plastigage (see page 7-7).
6. Install the bearing halves in the engine block and the
connecting rods.
7. Apply new engine oil to the inside of the main
bearings and the connecting rod bearings.
8. Install the CKP pulse plate (A) on the crankshaft (B);
face the marked side (C) toward the transmission, and
align the tab (D) on the CKP pulse plate with the
groove (E) on the crankshaft.

8 x 1.0 mm

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11. Inspect the connecting rod bolts (see page 7-23).
12. Apply new engine oil to the threads and flanges of the
connecting rod bolts.
13. Seat the connecting rod journals into connecting rod
No. 1 and connecting rod No. 4. Line up the mark (A)
on the connecting rod and the connecting rod cap,
then install the connecting rod caps and the
connecting rod bolts finger-tight.

9. Hold the crankshaft so that connecting rod journal No.

2 and connecting rod journal No. 3 are straight up,
and lower the crankshaft into the engine block.

14. Rotate the crankshaft clockwise, and seat the

connecting rod journals into connecting rod No. 2 and
connecting rod No. 3. Line up the mark on the
connecting rod and the connecting rod cap, then
install the connecting rod caps and the connecting rod
bolts finger-tight.
15. Torque the connecting rod bolts to 9.8 N-m (1.0 kgf-m,
7 Ibf-ft).
 n S

16. Tighten the connecting rod bolts an additional 90 °. 20. Apply liquid gasket (P/N 08717-0004, 08718-0003,
08718-0004, or 08718-0009) to the engine block
NOTE: Remove the connecting rod bolt if you
mating surface of the bearing cap bridge/No. 5 main
tightened it beyond the specified angle, and go back
bearing cap. Install the component within 5 minutes
to step 11 of the procedure. Do not loosen it back to
of applying the liquid gasket.
the specified angle.
NOTE:
• Apply a 2.5 mm (0.098 in) diameter bead of liquid
gasket 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.

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17. Install the main bearing caps with facing the arrows
(A) the cam chain side on the bearing cap bridge.

21. Put the bearing cap bridge on the engine block.

22. Apply new engine oil to the threads and the flange of
the bearing cap bolts.
23. Torque the bearing cap bolts in sequence to 25 N-m
(2.5 kgf-m, 18 Ibf-ft).

© © (D © ®
18. Remove all of the old liquid gasket from the bearing
cap bridge/No. 5 main bearing cap mating surfaces.
19. Clean and dry the bearing cap bridge/No. 5 main
bearing cap mating surfaces.
Crankshaft Installation (cont'd)

24. Tighten the bearing cap bolts an additional 40 °. 29. Measure the distance between the cylinder block (A)
and the crankshaft oil seal (B).
Oil Seal Installed Height:
0.2—1.2 mm (0.008-0.047 in)

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25. Clean the excess liquid gasket off the engine block.
26. Clean and dry the crankshaft oil seal housing.
27. Apply a light coat of new engine oil to the lip of the
crankshaft oil seal.
28. Using the driver handle (A) and the oil seal driver
30. Install the oil pump (A) with a new O-ring (B).
attachment, 96 mm (B), to drive a new crankshaft oil
seal squarely into the block to the specified installed
height.
A
07749-0010000

32. Install the oil pan (see page 7-28).

33. Install the cylinder head (see page 6-46).
 CKP Pulse Plate Replacement

34. Connect the CKP sensor connector (A), then install the 1. Remove the crankshaft from the engine block (see
CKP sensor cover (B). page 7-11).
2. Remove the CKP pulse plate (A) from the crankshaft
(B).
NOTE: Be careful not to damage the journals and the
CKP pulse plate.

8 x 1.0 mm

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35. Install the harness cover (C).
36. M/T model: Install the flywheel (see page 12-16), the
clutch disc, and the pressure plate (see page 12-18).
37. A/T model: Install the drive plate (see page 14-200).
38. Install the transmission. 3. Install the CKP pulse plate on the crankshaft; face the
• M/T model (see page 13-11) marked side (C) toward the transmission, and align
• A/T model (see page 14-201) the tab (D) on the CKP pulse plate with the groove (E)
on the crankshaft.
39. Install the engine/transmission (see page 5-10).
4. install the crankshaft on the engine block (see page
NOTE: When any crankshaft main or connecting rod 7-23).
bearing is replaced, run the engine at idle until it
reaches normal operating temperature, then continue
to run it for about 15 minutes.
Oil Pan Installation

1. Remove all of the old liquid gasket from the oil pan 4. Apply liquid gasket (P/N 08717-0004, 08718-0003,
mating surfaces, the bolts, and the bolt holes. 08718-0004, or 08718-0009) to the engine block
mating surface of the oil pan and to the inside edge of
2. Clean and dry the oil pan mating surfaces and the
the threaded bolt holes. Install the component within
O-ring groove.
5 minutes of applying the liquid gasket.
3. Install a new oil pan gasket (A), a new O-ring (B), and
NOTE:
the dowel pins (C) on the oil pan.
• Apply a 2.5 mm (0.098 in) diameter bead of liquid
gasket along the broken line (A).
• Apply a 5.0 mm (0.197 in) diameter bead of liquid
gasket to the shaded area (B).
• Apply a 3.0 mm (0.118 in) diameter bead of liquid
gasket along the broken line (C).
• 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

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liquid gasket, remove the old liquid gasket and
residue, then reapply new liquid gasket

— A: 2.5 mm (0.098 in)

B: 5.0 mm (0.197 in)
C: 3.0 mm (0.118 in)
D .
A, B,C
5. Install the oil pan. 6. Tighten the bolts in three steps. Wipe off the excess
liquid gasket from crankshaft pulley end and the
NOTE;
flywheel/drive plate end.
• Wait at least 30 minutes before filling the engine
with oil. Specified torque
• Do not run the engine for at least 3 hours after ®: 24 N m (2.4 kgfm, 17 Ibf ft)
installing the oil pan. ® - @ : 12 N-m (1.2 kgfm, 9 Ibf-ft)
• Make sure to install the bolts in the correct locations
according to size.

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(cont'd)
Oil Pan Installation (cont'd)

7. Install the clutch case cover/torque converter case 8. Connect the CKP sensor connector (A), then install the
cover (A), and install the transmission mounting bolts CKP sensor cover (B).
(B).
M /T model

B
1 2 x 1 .2 5 mm
64 N-m (6.5 k g fm , 47 Ibf-ft)

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9. Install the dipstick tube (A) with a new O-ring (B), then
install the dipstick.

A/T model

6 x 1.0 mm
12 N*m (1.2 k g fm , 9 Ibf-ft)

10. M/T model: Install the torque rod bracket (see page
5-30).
11. If the engine is still in the vehicle, do steps 12 through
16.
 Transmission End Crankshaft Oil
Seal Installation - In Car
12. A/T model: Install the shift cable cover (A). Special Tools Required
. Driver Handle, 15 x 135L 07749-0010000
• Oil Seal Driver Attachment, 96 mm 07ZAD-PNAA100

1. Remove the transmission.

• M/T model (see page 13-7)
• A/T model (see page 14-193)
2. M/T model: Remove the pressure plate (see page
12-14), the clutch disc (see page 12-15), and the
flywheel (see page 12-16).
3. A/T model: Remove the drive plate (see page 14-200).
4. Clean and dry the crankshaft oil seal housing.
5. Apply a light coat of new engine oil to the lip of the
crankshaft oil seal.

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6. Using the driver handle, 15x 135 L (A), and the oil seal
(1.2 k g fm , 9 Ib f ft) driver attachment, 96 mm (B), to drive a new
13. Install the A/C compressor (see step 33 on page 5-16). crankshaft oil seal squarely into the engine block to
the specified installed height.
14. Install the driveshaft heat shield (see step 28 on page
5-15). A

15. Install the drive belt (see page 4-29).

16. Refill the engine with engine oil (see step 4 on page
8- 10).
Transmission End Crankshaft Oil Drain Bolt/Sealing Bolt Installation
Seal Installation - In Car (cont'd)
7. Measure the distance between the cylinder block (A) NOTE:
and the crankshaft oil seal (B). • When installing the drain bolt (A), always use a new
Oil Seal Installed Height washer.
0 .2 -1 .2 mm (0.008-0.047 in) • When installing the sealing bolt(s) (B), always use a
new bolt(s) and washer(s) (C).
A B
28 x 1.0 mm 24 x 1.5 mm
78 N-m 75 N-m
(8.0 kgf-m, 58 Ibf-ft) (7.6 kgf m, 55 Ibf-ft)

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24 x 1.5 mm
8. M/T model: Install the flywheel (see page 12-16), the 75 N-m (7.6 k g fm , 55 Ib f ft)
Replace.
clutch disc, and the pressure plate (see page 12-18).
9. A/T model: Install the drive plate (see page 14-200).
10. Install the transmission.
• M/T model (see page 13-11)
• A/T model (see page 14-201)