Replacement

REMOVAL
1. Remove engine assembly from body as previously outlined.





2. Remove clutch cover, clutch disc and flywheel (drive plate for A/T).
Special Tool (A): 09924-17810 or equivalent
3. Remove crankshaft pulley, timing belt and crankshaft timing pulley.
4. Remove cylinder head assembly.
5. Remove oil pan and oil pump strainer.





6. Remove oil pump.





7. Remove oil seal housing.
8. Remove connecting rod bearing caps.





9. Loosen crankshaft bearing cap bolts in such order as indicated in figure a little at a time and remove bearing caps.
10. 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, bearing caps, connecting rods, rod bearings, rod bearing caps, pistons and piston rings are in combination sets. Do not disturb such combination and make sure that each part goes back to where it came from, when installing.





1. Install main bearings to cylinder block. One of two halves of main bearing, has an oil groove. Install it to cylinder block, and the other half without oil groove to bearing cap. Make sure that two halves are painted in the same color.





2. Install thrust bearings to cylinder block between No.2 and No.3 cylinders. Face oil groove sides to crank webs.
3. Install crankshaft to cylinder block.





4. Install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order 1, 2,3,4 and 5, starting from pulley side. After installing bearing cap stiffeners, tighten bearing cap bolts in such order as shown in figure a little at a time and repeat it till they are tightened to specified torque.
Tightening Torque (a): 54 Nm (5.4 kg-m, 39.0 ft. lbs.).

NOTE: After tightening cap bolts, check to be sure that crankshaft rotates smoothly when turning it by 8.0 Nm (0.8 kg-m, 96 inch lbs.) torque or below.





5. Install new gasket and oil seal housing. Do not reuse gasket removed in disassembly. Apply engine oil to oil seal lip before installation. Tighten housing bolts to specification.
Tightening Torque (a): 11 Nm (1.1 kg-m, 8.0 ft. lbs.)

NOTE: As there are two types of housing bolts, refer to figure for their correct use.

After installing oil seal housing, gasket edges might bulge out; if so, cut them off to make them flush with cylinder block and oil seal housing.
6. Install oil pump.





7. Install flywheel Manual Transmission (M/T model) or drive plate Automatic Transmission (A/T model). Using special tool, lock flywheel or drive plate, and torque its bolts to specification.
Special Tool (A): 09924-17810 or equivalent
Tightening Torque (a): 78 Nm (7.8 kg-m, 56.5 ft. lbs.)
8. Install pistons and connecting rods as previously outlined.
9. Install oil pump strainer and oil pan as previously outlined.





10. Install cylinder head assembly to cylinder block as previously outlined.

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.

11. Install camshaft, crankshaft timing belt pulley, timing belt, crankshaft pulley, water pump pulley, etc., as previously outlined.
12. Install clutch to flywheel (for M/T vehicle).





13. Install engine mountings and brackets.
Tightening Torque:
(a): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
(b): 45 Nm (4.5 kg-m, 32.5 ft. lbs.)
14. Install engine assembly to vehicle as previously outlined.