Installation Procedure

Fig 1: Inspecting Crankshaft End Play

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With the crankshaft and bearings in place, plastic gage all bearing clearances. Refer to Crankshaft and Bearings Cleaning and Inspection .
Inspect the crankshaft end play with the crankshaft bearings installed.
Inspect for permissible crankshaft end play. Refer to Crankshaft and Bearings Cleaning and Inspection .

Fig 2: Checking Crankshaft Journal For Out-Of-Round Runout

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With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft bearings and the middle crankshaft journal for permissible out-of-round runout. Refer to Engine Mechanical Specifications .

Fig 3: Installing Crankshaft

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Coat the crankshaft bearings with engine oil.
Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
Install the crankshaft bearings in he engine block.
Install the crankshaft.

Fig 4: Using J 45059 To Tighten Bearing Caps

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Install the crankshaft bearings to the crankshaft bearing caps.
Install the crankshaft bearing caps.

NOTE: Refer to Fastener Notice .

NOTE: Do not reuse crankshaft bearing cap bolts. Failure to replace the crankshaft bearing cap bolts can lead to crankshaft bearing cap bolt breakage or crankshaft bearing failure. A broken crankshaft bearing bolt can lead to extensive engine damage.

Install the new crankshaft bearing bolt.
Tighten: Tighten the crankshaft bearing cap bolts to 50 N.m (37 lb ft). Using the J 45059 (1) or the KM-470-B , tighten the crankshaft bearing cap bolts another 45 degrees.
Install the upper connecting rod bearings to the connecting rods.
Install the lower connecting rod bearings to the connecting rod bearing caps.

Fig 5: View Of Connecting Rod Bearing Caps

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Install the connecting rod bearing caps to the connecting rods.
Install the new connecting rod bearing cap bolts.
Tighten: Tighten the connecting rod bearing cap bolts to 25 N.m (18 lb ft). Using the J 45059 or the KM-470-B , tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees.

Fig 6: Identifying Oil Pump Retaining Bolts

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Install the oil pump.
Install the oil pump retaining bolts (1).
Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb in).

Fig 7: View Of Oil Pan

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Install the oil pump pickup tube.
Install the oil pump pickup tube bolts.
Tighten: Tighten the oil pump/pickup tube bolts to 10 N.m (89 lb in).

Fig 8: View Of Oil Pan

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Install the oil pan gasket to the oil pan.
Install the oil pan.

IMPORTANT: Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan.

Install the oil pan retaining bolts.
Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 lb in).
Rotate the engine on the OTC 1726 .

Fig 9: View Of Timing Belt Cover And Bolts

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Install the rear timing belt cover.
Install the rear timing belt cover bolts.
Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 lb in).

Fig 10: View Of Timing Belt Tensioner And Bolts

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Install the crankshaft timing belt gear.
Install the timing belt automatic tensioner.
Install the timing belt automatic tensioner bolts.
Tighten: Tighten the timing belt automatic tensioner bolts to 25 N.m (18 lb ft).
Install the timing belt idler pulley.
Install the timing belt idler pulley bolt.
Tighten: Tighten the timing belt idler pulley bolt to 40 N.m (30 lb ft).

Fig 11: View Of Intake And Exhaust Camshaft

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NOTE: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

Install the intake camshaft gear.
Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.
Tighten: Tighten the intake camshaft gear bolt to 67.5 N.m (49 lb ft).
Install the exhaust camshaft gear.
Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.
Tighten: Tighten the exhaust camshaft bolt to 67.5 N.m (49 lb ft).

Fig 12: View Of Ignition Wires And Spark Plugs

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Install the timing belt. Refer to Timing Belt Replacement .
Adjust the timing belt tension. Refer to Timing Belt Inspection .
Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear valve cover-to-cylinder head seal.
Install the valve cover and the valve cover gasket.
Install the valve cover washers.
Install the valve cover nuts.
Tighten: Tighten the valve cover nuts to 9 N.m (80 lb in).

Fig 13: View Of Timing Belt Cover Bolts

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Connect the ignition wires to the spark plugs.
Install the engine cover.
Install the engine cover bolts.
Tighten: Tighten the engine cover bolts to 3 N.m (27 lb in).
Connect the crankcase ventilation tube to the valve cover.
Install the upper and lower front timing belt cover.
Install the upper and lower front timing belt cover bolts.
Tighten: Tighten the upper and lower front timing belt cover bolts to 10 N.m (89 lb in).
Install the power steering pump, if equipped.
Install the power steering pump mounting bolts.
Tighten: Tighten the power steering pump mounting bolts to 25 N.m (18 lb in).
Install the engine lifting device.
Remove the engine from the OTC 1726 .

Fig 14: Installing New Crankshaft Rear Oil Seal Using J36972

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Install a new crankshaft rear oil seal using the J 36972 (1) or KM-635 .

Fig 15: View Of Flywheel

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Install the flywheel.
Install the flywheel bolts.
Tighten: Tighten the flywheel bolts to 35 N.m (25 lb ft). Use the J 45059 or KM-470-B to tighten the flywheel bolts 30 degrees plus 15 degrees. For the manual transaxle, tighten the flexible plate bolts to 60 N.m (44 lb ft).
Install the engine. Refer to Engine Replacement .