Crankshaft: Service and Repair

DISASSEMBLY
1. Remove cylinder head assembly (1). Refer to Cylinder head.
2. Remove oil pan (3).

CAUTION: Take care not to damage or deform the sealing flange surface of crankcase.

3. Remove oil pan support (4).
4. Remove oil strainer (5).
5. Remove oil pump assembly (5).
6. Balance unit assembly.
7. Remove piston and connecting rod assembly (7). Refer to Piston, Piston Ring and Connecting Rod.
8. Remove flywheel.
9. Remove rear oil seal and oil baffle plate.
10. Remove main bearing cap (8).
11. Remove crankshaft (9).
12. Remove crankshaft pulse pickup sensor disc.

INSPECTION AND REPAIR
1. Crankshaft





Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set.

Thrust Clearance
Standard: 0.01 mm - 0.02 mm (0.0004 inch - 0.0008 inch)
Limit: 0.21 mm (0.0118 inch)

Main Bearing Clearance
1. Remove the bearing caps and measure the oil clearance.
2. Remove the main bearing cap fixing bolts. Arrange the removed main bearing caps in the cylinder number order. Remove the main bearings.
3. Remove the crankshaft. Remove the main bearings.
4. Clean the upper and lower bearings as well as the crankshaft main journal.
5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original position.





8. Apply plastigage to the crankshaft journal unit as shown in the illustration.
9. Install main bearing caps, and tighten each bolt to the specified torque

Main bearing caps bolts.
Torque:
1st step: 50 Nm (37 ft. lbs.)
2nd step: 45°
3rd step: 15°
Torque: 39 Nm (29 ft. lbs.)





10. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft.

Standard: 0.015 mm - 0.04 mm (0.0007 inch - 0.O016 inch)
Limit: 0.12 mm (0.0047 inch)

11. Clean the plastigage from the bearings and the crankshaft.
Remove the crankshaft and the bearings.

Crankshaft (12) Inspection
Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions.

INSPECTION AND REPAIR





1. Carefully set the crankshaft. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced.

Runout: 0.03 mm (0.0012 inch)





2. Measure the diameter and the uneven wear of main journal and crank pin. If the crankshaft wear exceeds the specified limit, crankshaft must be replaced.

Main journal diameter: 57.934 mm - 57.980 mm (2.259 inch - 2.261 inch)
Crank pin diameter: 48.939 mm - 48.982 mm (1.909 inch - 1.91 inch)

Crankshaft Bearing Selection





When installing new crankshaft bearings or replacing bearings, refer to the selection table. Select and install the new crankshaft bearings.

NOTE: Take care to ensure the bearings are positioned correctly.

Crankshaft pulse pickup sensor disc inspection and repair.
Inspect the crankshaft pulse pickup sensor disc for excessive wear and damage.





Replace the crankshaft pulse pickup sensor disc if the inspection exceeds wear and damage.

REASSEMBLY
1. Crankshaft (12).
- Install the crankshaft pulse pickup sensor disc.

Torque: 13 Nm (10 ft. lbs.)

- Install the main bearings to the cylinder block and the main bearing caps.
- Be sure that they are positioned correctly.
- Apply new engine oil to the upper and lower main bearing faces.

NOTE: Do not apply engine oil to the main bearing back faces.

- Carefully mount the crankshaft.
- Apply engine oil to the thrust washer.
- Assemble the thrust washer to the No.3 bearing journal. The oil grooves must face the crankshaft.
- Tighten the crankshaft bearing cap bolts in 3 steps:

1st step: 50 Nm (36 ft. lbs.)
2nd step: 45°
3rd step: 15°





2. Rear oil seal (10).
- Coat lip of seal rings thinly with protective grease.
- Install seal ring into cylinder block, use J-42616 (1) and J-42613 (2).





3. Flywheel (9).
1. Thoroughly clean and remove the oil from the threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then install the washer.
4. Use stopper (J-42618) to hold the crankshaft.
5. Prevent from rotating.
Tighten the flywheel bolts in 3 steps:

1st step: 65 Nm (48 ft. lbs.)
2nd step: 30°
3rd step: 15°

NOTE: Do not reuse the bolt.

4. Piston and connecting rod assembly (8)
- Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned.





- Piston rings position (A) every 180°.
Oil scraper rings (B)-offset 25 to 50 mm / 1 to 2 inch to left and right from gap of intermediate ring.
- Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine.
- Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps.





- Arrow (1) on piston head points to engine timing side, bead on connecting rod points to flywheel side.
- Tighten the bolts in 3 steps:

1st step: 35 Nm (25 ft. lbs.)
2nd step: 45°
3rd step: 15°

5. Install the balance unit assembly and tighten the bolts in 2 steps:

1st step: 20 Nm (14 ft. lbs.)
2nd step: 45°

Refer to the Balance Unit Assembly section.
6. Install oil pump assembly (5), refer to Oil Pump.
7. Install oil strainer.

Torque: 8 Nm (5.8 ft. lbs.)

8. Install oil pan support and tighten the bolts to the specified torque.

Torque: 20 Nm (14 ft. lbs.)

9. Install oil pan.
1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB-1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead.
3. The oil pan support must be installed within 5 minutes after sealant application.
4. Tighten the bolts in two steps.

1st step: 8 Nm (5.8 ft. lbs.)
2nd step: 30°

10. Install cylinder head assembly, refer to Cylinder Head.