Crankshaft Inspection and Repair
CRANKSHAFT INSPECTION AND REPAIR
1. MEASURE CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial gauge, measure the runout at the center journal.
Maximum circle runout: 0.1mm (0.004 in.)
If the runout is greater than maximum, replace the crankshaft.
HINT: Use a long spindle on the dial gauge.
2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of the main journal and crank pin.
Main journal diameter: 59.984 - 60.000 mm (2.3616 - 2.3622 in.)
Crank pin diameter: 52.988 - 53.000 mm (2.0861 - 2.0866 in.)
If journals are worn, regrind or replace the crankshaft.
(b) Measure the journals for out-of-round and taper as shown.
Maximum taper: 0.01mm (0.0004 in.)
Maximum out-of-round: 0.01mm (0.0004 in.)
If taper and out-of-round are greater than maximum, regrind and/or replace the crankshaft.
3. GRIND CRANK PIN AND/OR MAIN JOURNAL, IF NECESSARY
(a) Grind the crank pins and/or main journals to the undersized finished diameter.
Bearing size (U/S 0.25)
Main journal finished diameter: 59.701 - 59.711 mm (2.3504 - 2.3508 in.)
Crank pin finished diameter: 52.701 - 52.711 mm (2.0748 - 2.0752 in.)
(b) Install a new pin and/or main undersized bearings.
CRANKSHAFT OIL SEALS REPLACEMENT
HINT: There are 2 methods (A and B) to replace the oil seal which are as follows:
1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If timing chain cover is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09223-50010
(c) Apply MP grease to the oil seal lip.
B. If timing chain cover is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09223-50010
2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030,09608-35014 (09608-06020)
(c) Apply MP grease to the oil seal lip.
B. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030,09608-35014 (09608-06020)
Installation Of Crankshaft, Piston And Connecting Rod Assembly
HINT:
- Thoroughly clean all parts to be assembled.
- Before installing parts, apply new engine oil to all sliding and rotating surfaces.
- Replace all gaskets, 0-ring and oil seals with new parts.
1. INSTALL MAIN BEARINGS
Install the bearing in the cylinder block and bearing caps.
NOTICE: Install the upper bearing with the oil hole in the block.
2. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.3 main bearing cap position of the block with the oil grooves facing outward.
3. PLACE CRANKSHAFT ON CYLINDER BLOCK
4. INSTALL MAIN BEARING CAPS WITH LOWER THRUST WASHERS
HINT: Each bearing cap is numbered.
(a) Install the thrust washers on the No.3 bearing cap with the grooves facing outward.
(b) Install the bearing caps in their proper locations.
(c) Apply a light coat of engine oil on the threads and under the cap bolt heads.
(d) Install and tighten the cap bolts in 2 or 3 passes and in the sequence shown.
Torque: 103 N.m (1,050 kgf-cm. 76 ft-lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance.
5. INSTALL PISTON AND CONNECTING ROD ASSEMBLY
(a) Cover the rod bolts with a short piece of hose to protect the crankshaft from damage.
(b) Lubricate the cylinder bore and rod journal with clean engine oil.
(c) Using a ring compressor. tighten the compressor snugly but NOTtightly against the piston and gently tap the correctly numbered piston and rod assembly into its cylinders with a wooden hammer handle or similar object. Make sure the notch and mark are facing forward.
HINT: If the ring compressor is wound too tightly around the piston, the bottom edge of the ring compressor will catch against the beveled surface at the top of the cylinder when tapping the piston in.
6. INSTALL CONNECTING ROD CAPS
(a) Match the numbered cap with the numbered rod.
(b) Install the cap with the front mark facing forward.
(c) Apply a light coat of engine oil on the threads and under the rod nuts.
(d) Install and tighten the rod nuts alternately and in 2 or 3 passes.
Torque: 69 N.m (700 kgf.cm, 51 ft.lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the rod thrust clearance.
MEASURE CRANKSHAFT THRUST CLEARANCE
Using a dial gauge, measure the crankshaft thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard clearance: 0.02 - 0.22mm (0.0008 - 0.0087 in.)
Maximum clearance: 0.3mm (0.012 in.)
If the clearance is greater than maximum, replace the thrust washers as a set and/or crankshaft.
Thrust washer thickness:
Standard: 2.690 - 2.740 mm (0.1059 - 0.1079 in.)
0/S 1.25
2.753 - 2.803 mm (0.1084 - 0.1104 in.)
0/S 2.50
2.815 - 2.865 mm (0.1108 - 0.1128 in.)
CYLINDER BLOCK ASSEMBLY
1. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 4 bolts. Torque the bolts.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
2. INSTALL OIL STRAINER
(a) Clean the oil strainer.
(b) Place the gasket in place and install the oil strainer assembly with the 4 bolts. Torque the bolts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
3. INSTALL FUEL FILTER BRACKET AND FILTER
4. INSTALL KNOCK CONTROL SENSOR
5. INSTALL OIL PRESSURE SENDER GAUGE
6. A/T:
INSTALL FLEXIBLE HOSE CLAMP
7. INSTALL RH ENGINE MOUNTING BRACKET, CHAMBER STAY AND GROUND STRAP
8. INSTALL OIL FILTER
9. INSTALL CHAIN TENSIONER
Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
10. INSTALL CHAIN DAMPERS
Torque: 22 N.m (220 kgf.cm, 16 ft.lbf)
11. INSTALL GENERATOR BRACKET AND LH ENGINE MOUNTING BRACKET
12. INSTALL TIMING CHAIN
13. INSTALL GENERATOR
14. INSTALL CYLINDER HEAD
15. REMOVE ENGINE STAND
16. INSTALL REAR END PLATE
17. INSTALL FLYWHEEL OR DRIVE PLATE
Install the flywheel (M/T) or spacer, drive plate, spacer (A/T) on the crankshaft with the 6 bolts. Torque the bolts.
Torque:
M/T: 108 N.m (1,100 kgf.cm, 80 ft.lbf.
A/T: 83 N.m (850 kgf.cm, 61 ft.lbf)