Replacement
REMOVAL
1. Remove engine assembly from vehicle as previously outlined.
2. Remove clutch and flywheel (for Manual Transmission (M/T) vehicle) or drive plate (for Automatic Transmission (A/T) vehicle).
Special Tool (A): 09924-17810 or equivalent.
3. Remove throttle body, intake manifold, exhaust manifold.
4. Remove oil pan and oil pump strainer.
5. Remove oil pump.
6. Remove cylinder head cover.
7. Remove timing chain cover.
8. Remove timing chain guide, chain tensioner, tensioner adjusters, 2nd timing chain and 1st timing chain.
9. Remove cylinder head assembly.
10. Remove pistons and connecting rods.
11. Remove Crankshaft Position (CKP) sensor.
12. Remove water pump and heater outlet pipe.
13. Remove engine side mounting brackets (right and left).
14. Loosen crankcase bolts, following sequence in figure and remove them.
15. Remove crankshaft from cylinder block.
INSTALLATION
NOTE:
^ All parts to be installed must be perfectly clean.
^ Be sure to oil crankshaft journals, journal bearings, thrust bearings, crankpins, connecting rod bearings, pistons, piston rings and cylinder bores.
^ Journal bearings, crankcase (bearings caps), connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do now disturb combination and try to see that each part goes back to where it came from, when installing.
^ Clean mating surface of cylinder block and lower crankcase, remove oil, old sealant and dust from mating surface.
1. Fit main bearings to cylinder block. One of two halves of main bearing, has oil groove. Install this half with oil groove to cylinder block, and another half without oil groove to lower crankcase. Make sure that two halves are painted in the same color.
2. Install O-ring to cylinder block.
3. Fit thrust bearings to cylinder block between No.2 and No.3 cylinders. Face oil groove sides to crank webs.
4. Put crankshaft with oil pump chain to cylinder block.
5. Apply sealant "A" to lower crankcase mating surface area as shown in figure.
"A": Sealant 99000-31150 or equivalent.
6. Install lower crankcase to cylinder block. Apply oil to crankcase bolts before installing them. Tighten crankcase bolts, following sequence in figure. Tighten crankcase bolts to specified torque.
Tightening Torque:
(a): 58 Nm (5.8 kg-m, 42.0 ft. lbs.)
(b): 27 Nm (2.7 kg-m, 19.5 ft. lbs.)
NOTE: After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
7. Install rear oil seal by using plastic hammer and special tools.
Special Tools:
(A): 09911-97710 or equivalent.
(B): 09911-97810 or equivalent.
8. Install CKP sensor.
9. Install flywheel Manual Transmission (M/T vehicle) or drive plate Automatic Transmission (A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts applied with thread lock cement to specification.
"A": Thread lock 99000-32110 or equivalent.
Special Tool (A): 09924-17810 or equivalent.
Tightening Torque (a): 70 Nm (7.0 kg-m, 51.0 ft. lbs.)
10. Install engine side mounting brackets (right and left). Tighten bracket bolts to specified torque.
Tightening Torque (a): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
11. Install water pump and heater outlet pipe.
12. Install pistons and connecting rods as previously outlined.
13. Install cylinder head assembly to cylinder block.
NOTE: Tighten cylinder head bolts to specified torque as previously outlined. Whenever installing cylinder head to new cylinder block, use following procedure to tighten cylinder head bolts.
^ Tighten cylinder head bolts to specified torque as previously outlined and loosen them once till tightening torque becomes "zero." And then torque them to specification again.
14. Install timing chains, timing chain tensioner, timing chain guide, timing chain sprockets, timing chain cover, crankshaft pulley, water pump pulley, etc., as previously outlined.
15. Install oil pump strainer and oil pan.
16. Install clutch to flywheel (for M/T vehicle) or clutch installation.
17. Install engine assembly to vehicle as previously outlined.