Crankshaft
Crankshaft
Crankshaft and Associated Parts
Disassembly
1. Remove cylinder head assembly (1).
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).
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 for Bearing
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 (0.0083 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°
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 (0.0006 inch - 0.0016 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 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 for Crankshaft
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:
White color 57.974 to 57.981 mm (2.2824 to 2.2871 inch)
Green color 57.981 to 57.988 mm (2.2871 to 2.2830 inch)
Brown color 57.988 to 57.995 mm (2.2830 to 2.2833 inch)
Crank pin diameter:
Standard (No color) 48.970 - 48.988 mm (1.9279 to 1.9287 inch)
Blue (U/S 0.25) 48.720 to 48.738 mm (1.9181 to 1.9188 inch)
White (U/S 0.25) 48.470 to 48.488 mm (1.9083 to 1.9090 inch)
NOTE: Take average of several measurements at different points.
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 (113 inch 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 baring cap bolts in 3 steps:
1st step: 50 Nm (36 ft. lbs.)
2nd step: 45°
The new bolts must be used.
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 flywheel for prevent from rotating.
5. Tighten the flywheel bolts in 2 steps:
1st step: 65 Nm (48 ft. lbs.)
2nd step: 30° -45°
Note: Do not reuse the bolt
6. Piston and connecting rod assembly.
^ 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 a.
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 (1) 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.
^ Dot (1) on piston head points to engine timing side, bead on connecting rod points to flywheel side.
^ Tighten the flywheel bolts in 2 steps:
1st step: 35 Nm (26 ft. lbs.)
2nd step: 45°
New bolts must be used.
7. Install the balance unit assembly and tighten the bolts in 2 steps:
1st step: 20 Nm (14 ft. lbs.)
2nd step: 45°
8. Install oil pump assembly (5).
9. Install oil strainer.
Torque: 8 Nm (69 inch lbs.)
10. Install oil pan support and tighten the bolts to the specified torque.
Clean sealing surface before assembly, and apply four beads of sealant as shown.
Torque: 20 Nm (14 ft. lbs.)
11. Install oil pan.
Tighten the oil pan bolts.
Torque: 8 Nm (69 inch lbs.)
12. Install cylinder head assembly.