Rear Main Seal

Removal & Installation

To Remove:

NOTE: Before conducting this procedure, drain the engine oil completely if applicable.

1. Remove the following
   • Intake manifold
   • V-belt
   • Crankshaft pulley
   • Timing belt cover
   • Timing belt assembly
   • Camshaft sprocket
   • Crankshaft sprocket
   • Generator and a/c compressor with their brackets
   • Cylinder head assembly
   • Clutch disc and cover
   • Flywheel. (MT model)

     Crank Shaft Stopper

   • Drive plate. (AT model) using st, lock crankshaft. St 498497100 crankshaft stopper
   • Oil separator cover
   • Water by-pass pipe for heater
   • Oil filter. St 18332aa000 oil filter wrench (outer diameter: 68 mm (2.68 inch) ) st 18332aa010 oil filter wrench (outer diameter: 65 mm (2.56 inch) )

     Oil Cooler

   • Oil cooler
   • Oil pan
   • Oil strainer stay
   • Oil strainer
   • Baffle plate
   • Water pipes
   • Water pump
   • Oil pump

     Service Hole Plug

   • Service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 inch)]

   Piston Cir-clip

2. Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, and then remove the piston cir-clip through service hole of #1 and #2 cylinders

3. Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN

   NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.

4. Remove the piston pins from #3 and #4 pistons
5. Remove the bolts which connect the cylinder block on the side of #2 and #4 cylinders
6. Back off the bolts which connect the cylinder block on the side of #1 and #3 cylinders two or three turns
7. Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts

8. Separate the cylinder blocks (LH) and (RH)

   CAUTION
   When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.

9. Remove the rear oil seal

To Install:

1. Remove oil in the mating surface of bearing and cylinder block before installation Apply a coat of engine oil to crankshaft pins
2. Position the crankshaft on #2 and #4 cylinder block

3. Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block
   • Fluid Packing: Part No. 004403007 THREE BOND 1215 Or Equivalent

     NOTE: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.

4. Apply engine oil to washers and thread of bolts

5. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (LH side)

6. Tighten the 10 mm cylinder block connecting bolts in alphabetical sequence shown in the figure (RH side)

7. Further tighten the LH side bolts (A - D) in alphabetical sequence

8. Further tighten the RH side bolts (E - J) in alphabetical sequence

9. Further tighten the LH side bolts (A - D) by 90° in alphabetical sequence

10. Further tighten the RH side bolts (E - J) by 90° in alphabetical sequence

11. Tighten the 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in the figure

12. Install the rear oil seal using ST1 and ST2. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

13. Position the top ring gap at (A) or (B) in the figure
14. Position the second ring gap at 180° on the reverse side for the top ring gap

15. Position the upper rail gap at (C) in the figure

16. Align upper rail spin stopper (D) with piston side surface hole (E)

17. Position the expander gap at (F) in the figure

18. Position the lower rail gap at (G) in the figure

    NOTE: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.

19. Install the cir-clip. Install the cir-clips in piston holes located opposite of service holes in cylinder block, when positioning all pistons in the corresponding cylinders.

    NOTE: Use new cir-clips.

20. Turn the cylinder block so that #1 and #2 cylinders face upward.
21. Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET
22. Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE

    NOTE: Piston front mark faces towards the front of the engine.

23. Apply a coat of engine oil to ST3, and then insert the ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE
24. Apply a coat of engine oil to the piston pin and insert piston pin into piston and connecting rod through service hole.
25. Using the ST, install the cir-clip.

    NOTE: Use new cir-clips.

26. Apply fluid packing around the service hole plug.
27. Install the service hole plug and gasket.

    NOTE: Use a new gasket.

28. Turn the cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
29. Install the following
    • Water pipe
    • Baffle plate
    • Torque specification: 6.4 Nm (4.7 ft. Lbs.)
    • Oil strainer and O-ring
    • Torque specification: 10 Nm (7 ft. Lbs.)
    • Oil strainer stay
    • Oil pan and apply fluid packing to the matching surfaces
    • Oil separator cover and apply fluid packing to the matching surfaces
    • Flywheel
    • Clutch disc and cover
    • Oil pump
    • Water pump and gasket
      1. Torque specification: First; 12 Nm (1.2 kgf-cm, 8.7 ft. Lbs.) Second; 12 Nm (1.2 kgf-cm, 8.7 ft. lbs.)

      NOTE: Be sure to use a new gasket.

    • Water by-pass pipe for heater
    • Oil cooler
    • Oil filter using st. St 18332aa000 oil filter wrench (outer diameter: 68 mm ) st 18332aa010 oil filter wrench (outer diameter: 65 mm )
    • Water by-pass pipe between oil cooler and water pump
    • Water pipe
            NOTE:Always use a new O-ring.

    • Cylinder head assembly
    • Oil level gauge guide and tighten the attaching bolt (lh side)
    • Rocker cover
    • Crankshaft sprocket
    • Camshaft sprocket
    • Timing belt assembly
    • Timing belt cover
    • Crankshaft pulley
    • Generator and A/C compressor brackets on cylinder head
    • V-belt
    • Intake manifold