Note: For manual transmission, install the end sleeve when replacing the crankshaft.
1. Press the crankshaft end sleeve using the special tool until the bottom of the special tool rests against the crankshaft.
2. Check the crankshaft bearing clearances using Plastigage.
3. Check the main bearing clearance using a Plastigage gauge.
4. Check the connecting rod bolts.
5. Place the bearing shells into the cylinder block and onto the connecting rods.
6. Apply engine oil to the main and connecting rod bearings.
7. Hold the crankshaft so that the connecting rod journals for cylinders #2 and #3 are on top and lower the crankshaft into the block.
8. Place the thrust washers (A) on journal No. 4 of the cylinder block.
9. Apply engine oil to the connecting rod bolt threads.
10. Install the crankpins into connecting rods #1 and #4. Align the mark (B) on the connecting rod and cap, then install the caps and tighten the bolts finger tight.
11. Turn the crankshaft clockwise and seat the journals in connecting rods No. 2 and No. 3. Align the mark on the connecting rod and cap, then install the caps and tighten the bolts by hand.
12. Tighten the connecting rod bolts to 20 Nm (2.0 kgf·m).
13. Tighten the connecting rod bolts by 90°.
14. Remove old sealant from the mating surfaces of the lower block, bolts and bolt holes.
15. Clean and dry the contact surfaces of the lower block.
16. Apply the sealant evenly, 08C70-K0234M, 08C70-K0334M
or 08C70-X0331S, on the contact surface of the cylinder block under the lower block and on the internal thread of the holes for the bolts.
Note: Do not install components if more than 5 minutes have passed since applying the sealant. Instead, reapply the sealant, removing any traces of the old one.
17. Install the lower block onto the cylinder block.
18. Tighten the bearing cap bolts in sequence to 29 Nm (3.0 kgf·m).
19. Tighten the bearing cap bolts by 56°.
20. Tighten the 8 mm bolts in sequence to 22 Nm (2.2 kgf·m).
21. Using a special tool, press the new seal into the block without tilting it to the required installation depth.
22. Measure the distance between the crankshaft (A) and the oil seal (B).
Seal installation depth: 5.5-6.5 mm
23. Install mud deflectors.
24. Install the oil pump.
25. Install the oil pan.
26. Install the cylinder head
27. Install the gearbox.
28. Install the engine assembly.