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Crankshaft and Piston Installation

Special Tools Required 

  1. Check the main bearing clearance  with plastigage.
  2. Check the connecting rod bearing clearance  with plastigage.
  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. Install the CKP pulse plate to the crankshaft .
  6. Lower the crankshaft (A) into the engine block, being careful not to damage the journals and the CKP pulse plate (B).
    Fig 1: Identifying Crankshaft And CKP Pulse Plate
    G08069145Courtesy of AMERICAN HONDA MOTOR CO., INC.
  7. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 3 journal.
    Fig 2: Identifying Thrust Washers
    G08069146Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the bearings (A) and the main bearing caps (B) with the arrow (C) facing the timing belt side of the engine block.
    Fig 3: Identifying Bearings And Main Bearing Caps Installation Position
    G08069147Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. 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).
  10. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in.
  11. Apply new engine oil to the piston, the inside of the ring compressor, and the cylinder bore.
  12. Attach the ring compressor to the piston/connecting rod assembly, and check that the bearing is securely in place.
  13. Position the piston/connecting rod assembly with the arrow (A) facing the timing belt side of the engine block.
    Fig 4: Positioning Piston/Connecting Rod Assembly With Arrow
    G08069148Courtesy of AMERICAN HONDA MOTOR CO., INC.
  14. 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.
    Fig 5: Pushing Downward Force On Ring Compressor By Using Wooden Handle Of Hammer
    G08069149Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Stop after the ring compressor pops free, and check the connecting rod-to-rod journal alignment before pushing the piston into place.
  16. Measure the diameter of each connecting rod bolt at point A and point B.
    Fig 6: Identifying Connecting Rod Bolt Diameter At Point A And B
    G08069150Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Calculate the difference in diameter between point A and point B.

    Point A- Point B = Difference in Diameter 

    Difference in Diameter 

    Specification: 0- 0.1 mm (0- 0.004 in) 

  18. If the difference in diameter is out of tolerance, replace the connecting rod bolt.
  19. Install the bearing (A), then line up the mark (B) on the connecting rod (C) and the rod cap (D).
    Fig 7: Identifying Bearing, Connecting Rod, Rod Cap, Bearing Mark And Bolts
    G08069151Courtesy of AMERICAN HONDA MOTOR CO., INC.
  20. Apply new engine oil to the bolt threads and flanges. Torque the bolts (E) to 20 N.m (2.0 kgf.m, 15 lbf.ft).
  21. Tighten the connecting rod bolt an additional 90 °.
    NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step  16 of the procedure. Do not loosen it back to the specified angle. Repeat steps  10 to  21 for the remaining cylinders.
    Fig 8: Identifying Specified Angle For Tightening Connecting Rod Bolt
    G08069152Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Tighten the main bearing cap bolts, then tighten the main bearing cap side bolts to the specified torque in the sequence as shown in illustration below. Repeat the torque sequence again to ensure the bolts are properly torqued.
    Fig 9: Main Bearing Cap Side Bolts With Tightening Sequence With Torque Specifications
    G08069153Courtesy of AMERICAN HONDA MOTOR CO., INC.
  23. Remove ail of the old liquid gasket from the engine block end cover mating surfaces, the bolts, and the bolt holes.
  24. Clean and dry the engine block end cover mating surfaces.
  25. Apply a light coat of new engine oil to the lip of the crankshaft oil seal.
  26. Using the driver handle, 15 x135 L and the oil seal driver attachment, 106 mm, drive in the new crankshaft oil seal (A) until the oil seal driver attachment bottoms on the engine block end cover.
    Fig 10: Installing Crankshaft Oil Seal Using Driver Handle And Attachment
    G08069154Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Apply liquid gasket, P/N 08717-0004, 08718-0003, 08718-0004, 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 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 the new liquid gasket.
    Fig 11: Identifying Diameter Bead Of Liquid Gasket
    G08069155Courtesy of AMERICAN HONDA MOTOR CO., INC.
  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.
    Fig 12: Dowel Pins, O-Rings And Engine Block End Cover On Engine Block With Torque Specifications
    G08069156Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
  30. Install a new crankshaft oil seal in the oil pump (see OIL PUMP OVERHAUL ).
  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, 08718-0003, 08718-0004, 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 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 the new liquid gasket.
    Fig 13: Identifying Diameter Bead Of Liquid Gasket
    G08069157Courtesy of AMERICAN HONDA MOTOR CO., INC.
  34. Apply a light coat of new engine oil to the lip of the crankshaft oil seal, and apply new engine oil to the new O-ring (A).
    Fig 14: O-Rings, Dowel Pins, Oil Pump, Baffle Plate, Oil Retainer With Torque Specifications
    G08069158Courtesy of AMERICAN HONDA MOTOR CO., INC.
  35. Install the dowel pins (B), then align the inner rotor with the crankshaft, and install the oil pump (C).
  36. Clean the excess oil off the crankshaft, and check that the oil seal is not distorted.
  37. Install the baffle plate (0), then install the oil strainer (E) with a new O-ring (F).
    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 oil pump.
  38. Install the rocker arm oil control solenoid/oil filter assembly (A), with a new rocker arm oil control solenoid filter (B).
    Fig 15: Rocker Arm Oil Control Solenoid/Oil Filter Assembly And Solenoid Filter With Torque Specifications
    G08069159Courtesy of AMERICAN HONDA MOTOR CO., INC.
  39. Install the oil pan .
  40. Install the timing belt drive pulley to the crankshaft:
  41. Install the cylinder heads:
  42. M/T model: Install the flywheel (see TRANSMISSION SIDE ).
  43. A/T model: Install drive plate (see DRIVE PLATE REMOVAL AND INSTALLATION ).
  44. Install the transmission:
  45. Install the engine/transmission (see ENGINE INSTALLATION ).
NOTE: When any crankshaft main 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.
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