Crankshaft
DISASSEMBLY
1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the cap number.
5. Remove the crankshaft position sensor wheel.
CAUTION: Mark the main bearing caps to permit reassembly in the original position and direction.
INSPECTION
CRANKSHAFT
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging. Correct or replace any defective part.
2. Inspect out-of-roundness and taper of crankshaft journal and pin.
Standard value
Crankshaft journal O.D: 50 mm (1.9685 inch)
Crankshaft pin O.D: 45 mm (1.7717 inch)
Crankshaft journal, pin out-of-roundness and taper 0.01 mm (0.0004 inch) or less
MAIN BEARINGS AND CONNECTING ROD BEARINGS
Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace the defective bearings.
OIL CLEARANCE MEASUREMENT
To check the oil clearance, measure outside diameter of the crankshaft journal and the crank pin and inside diameter of the bearing. The clearance measurement is the difference between the measured outside and inside diameters.
Standard value
Journal oil clearance NO. 1,2,4,5 0.028 - 0.046 mm (0.0011 - 0.0018 inch)
Journal oil clearance NO. 3 (center): 0.034 - 0.52 mm (0.0013 - 0.002 inch)
Pin oil clearance: 0.024 - 0.042 mm (0.0009 - 0.0017 inch)
PLASTIC GAUGE METHOD
A plastic gauge may be used to measure the clearance.
1. Remove oil, grease and any other dirt from bearings and journals.
2. Cut plastic gauge to the same length as the width of the bearing and place it parallel with the journal, off from the oil holes.
3. Install the crankshaft, bearings, and caps. Tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastic gauge at the widest point using the scale printed on the gauge package. If the clearance exceeds the repair limit, replace the bearing.
Should the standard clearance not be obtained even after bearing replacement, the journal should be ground to a recommended undersize, and a bearing of the same size should be installed.
OIL SEAL
Check front and rear oil seals for damage or worn lips. Replace any seat that is defective.
CRANKSHAFT POSITION SENSOR WHEEL
1. Remove the crankshaft position sensor wheel
2. Check the crankshaft position sensor wheel for damage, cracks and wear, and replace if necessary.
3. Check the clearance between the crankshaft position sensor wheel and the crankshaft position sensor with a depth gage.
Standard value:
Clearance between the crankshaft position sensor wheel and crankshaft position sensor: 0.5 - 1.5 mm (0.020 - 0.059 inch)
NOTE
1. Measure the depth of the top of the crankshaft position sensor wheel teeth and the outside of transaxle housing.
2. Measure the difference between the crankshaft position sensor length and depth.
3. The crankshaft position sensor length is the distance between the end of crankshaft position sensor and inner point of contractor face.
REASSEMBLY
1. Install the upper main bearing inserts in the cylinder block.
When reusing the main bearings, remember to install them by referring to the location marks made at the time of disassembly.
2. Install the crankshaft. Apply engine oil to the journals.
3. Install bearing caps and tighten cap bolts to the specified torque in the sequence of the center, No.2, No.4, front and rear caps.
Cap bolts should be tightened evenly in 2 to 3 stages before they are tightened to the specified torque. The caps should be installed with the arrow mark directed toward the crank pulley side of engine. Cap numbers must be correct.
Tightening torque
Main bearing cap bolt 55 - 60 Nm (550 - 600 kg.cm, 41 - 44 ft. lbs.)
Connecting rod cap bolt: 32 - 35 Nm (320 - 350 kg.cm, 24 - 26 ft. lbs.)
4. Make certain that the crankshaft turns freely and has the proper clearance between the center main bearing thrust flange and the connecting rod big end bearing.
Standard value
Crankshaft end play 0.05 - 0.175 mm (0.002 - 0.005 inch)
5. Install the oil seal in the crankshaft rear oil seal case. Use the Special Tool, Crankshaft Rear Oil Seal Installer (09231-21000) as shown. Press and fit the oil seal in all the way, being careful not to misalign it.
6. Install the rear oil seal case and gasket. Tighten the five bolts. Apply engine oil to the oil seal lips and crankshaft at the time of installation.
7. Install the rear plate and tighten the bolts.
8. Install the connecting rod caps.
9. Install the flywheel, front case, oil pan and timing belt.