Main Bearing, Crankshaft and Cylinder Block Removal and Installation
Precautions: General safety (00)
Removal
1)Remove engine assembly from vehicle. 
2)Remove flywheel (M/T model) or drive plate (A/T model).
3)Remove pistons and connecting rods.
4)Remove engine rear crankshaft oil seal housing (1).
5)Remove main bearing cap No.1 and No.2 bolts in numerical order gradually as shown in figure.
6)Remove main bearing caps.
7)Remove crankshaft from cylinder block.
8)Remove sensor plate and spring pin from crankshaft, if necessary.
9)Remove venturi plug, if necessary.
Installation
NOTICE:
•The engine will seize up if it is operated when the parts listed below are not properly lubricated.
Lubricate all the friction surfaces of these parts with engine oil before installing them.
When main bearing cap bolts are reused, check that main bearing cap bolts are not deformed exceeding the service limit referring to “Main Bearing Cap Bolt” under Main Bearing Inspection:M16A.
Lubricate all the friction surfaces of these parts with engine oil before installing them.
—Crankshaft journal
—Main bearing
—Thrust bearing
•Using main bearing cap bolts that are deformed exceeding the service limit could lead to engine problems.—Main bearing
—Thrust bearing
When main bearing cap bolts are reused, check that main bearing cap bolts are not deformed exceeding the service limit referring to “Main Bearing Cap Bolt” under Main Bearing Inspection:M16A.
1)Install venturi plug (1) and tighten venturi plug to specified torque, if removed.
2)Install sensor plate (1) using the following procedure, if removed.
a)Attach spring pin (2) to crankshaft (3).
b)Install sensor plate to crankshaft, spring pin into hole (4) and facing inside edge (5) outward as shown in figure.
c)Tighten bolts to specified torque.
| 6. | Crankshaft side |
3)Install main bearings to cylinder block and main bearing cap using the following procedure.
NOTE:
•Install main bearing halves (1) with oil groove (2) to cylinder block.
For ENG A-STOP model, install the main bearing half which has two holes (3) in the oil groove to the journal nearest to the crankshaft pulley.
•Install other main bearing halves to main bearing cap.
For ENG A-STOP model, install the main bearing half which has two holes (3) in the oil groove to the journal nearest to the crankshaft pulley.
| 4. | Crankshaft pulley side |
a)Fit the tab (1) on each bearing into groove (2) in cylinder block and main bearing cap.
b)Press bearing end (3) until it fully seats in cylinder block and main bearing cap.
c)Apply engine oil to sliding surface (4) of main bearing halves.
NOTICE:
If oil is present between the bearing’s outside surface (5) and the cylinder block or main bearing cap surface, the bearing could heat up to very high temperature, resulting in seizure.
Thoroughly wipe off any trace of oil that is present between the bearing’s outside surface (5) and the cylinder block or main bearing cap surface.
4)Install thrust bearings (1) to cylinder block between No.2 and No.3 cylinders.
NOTE:
Face oil groove (2) side to crank web.
5)Check that dowel pins (3) are installed to intake side of each journal.
6)Install crankshaft to cylinder block.
7)Install main bearing cap as follows.
NOTICE:
Using main bearing cap bolts that are deformed exceeding the service limit could lead to engine problems.
Before installing main bearing cap, check that main bearing cap No.1 bolts are not deformed exceeding the service limit referring to “Main Bearing Cap No.1 Bolt” under Main Bearing Inspection:M16A.
a)Point arrow mark on cap to crankshaft pulley side. Fit them in numerical order (“1” – “5”), starting from pulley side.
b)Apply engine oil to bolt thread and seat of main bearing cap No.1 bolt.
c)Tighten main bearing cap No.1 bolts to 30 N·m (3.1 kgf-m, 22.5 lbf-ft) in numerical order (“1” – “10”) as shown using a 12-point socket wrenches.
d)In the same manner as in Step c), tighten them to 50 N·m (5.1 kgf-m, 37.0 lbf-ft).
e)Turn all main bearing cap No.1 bolts 60° in numerical order as shown in figure.
f)Tighten main bearing cap No.2 bolts to 25 N·m (2.5 kgf-m, 18.5 lbf-ft) in numerical order (“11” – “20”) as shown.
Main bearing cap No.2 bolt (b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
Tightening torque
Main bearing cap No.1 bolt* (a): 30 N·m → 50 N·m → +60° (3.1 kgf-m → 5.1 kgf-m →+60°, 22.5 lbf-ft → 37.0 lbf-ft →+60°)Main bearing cap No.2 bolt (b): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
8)Check that crankshaft rotates smoothly when turning it by 12 N·m (1.2 kgf-m, 9.0 lbf-ft) torque or below.
9)Clean sealing surface between oil seal housing (2) and cylinder block.
10)Apply engine oil to new rear oil seal (1) and install it to engine rear crankshaft oil seal housing (2) using special tool.
Engine rear crankshaft oil seal installing position (depth)
“a”: 2.0 mm (0.08 in.)
11)Install dowel pin (2) to rear oil seal housing (1) as shown in figure.
12)Apply sealant to mating surface of rear oil seal housing (1).
Sealant amount for rear oil seal housing
Width: “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.)
13)Apply engine oil to oil seal lip, and then install engine rear crankshaft oil seal housing (1) using special tool.
14)Tighten new engine rear crankshaft oil seal housing bolts (2) to specified torque.
NOTE:
Check that engine rear crankshaft oil seal lip is not turned over after engine rear crankshaft oil seal housing is installed.
| 3. | Crankshaft side |
15)Install flywheel (M/T model) or drive plate (A/T model).
16)Install pistons and connecting rods.
17)Install cylinder head.
18)Install camshafts and tappets.
19)Install timing chain.
20)Install timing chain cover.
21)Install cylinder head cover.
22)Install oil pan.
23)Install engine assembly to vehicle.