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CRANKSHAFT INSPECTION/REPAIR

id011000502500

1. Measure the crankshaft end play using a dial gauge.

  • If it exceeds the maximum specification, replace the crankshaft or grind the crankshaft thrust side, and install the oversize bearing so that the specified end play is obtained.

Thrust bearing (mm {in})

Bearing size | Bearing thickness
--- | ---
ZJ, ZY, Z6
Standard | 2.500-2.550 {0.0985-0.1003}
0.25 {0.01} oversize | 2.625-2.675 {0.1034-0.1053}
0.50 {0.02} oversize | 2.750-2.800 {0.1083-0.1102}
0.75 {0.03} oversize | 2.875-2.925 {0.1132-0.1151}

  Standard end play
  0.080-0.282 mm {0.0032-0.0111 in}
  Maximum end play
  0.30 mm {0.0118 in}

2. Measure the crankshaft main journal runout on V-blocks using a dial gauge.

  • If it exceeds the maximum specification, replace the crankshaft.

  Maximum runout
  0.10 mm {0.0039 in}

3. Inspect the main journal diameter and crank pin diameter. Measurement positions total four and they are in the X and Y directions, at two points (A and B) as shown in the figure.

  • If not within the specification or exceeds the maximum off-round, replace the crankshaft or grind the journal to fit the oversize bearing.

Main journal diameter (mm {in})

Bearing size | Main journal diameter
--- | ---
ZJ, ZY, Z6
Standard | 49.938-49.956 {1.9661-1.9667}
0.25 {0.01} oversize | 49.688-49.706 {1.9562-1.9569}
0.50 {0.02} oversize | 49.438-49.456 {1.9463-1.9471}

  Maximum off-round
  0.05 mm {0.0019 in}

Crank pin journal diameter (mm {in})

Bearing size | Crank pin diameter
--- | ---
ZJ | ZY, Z6
Standard | 39.940-39.956 {1.5725-1.5730} | 47.940-47.956 {1.8874-1.8880}
0.25 {0.01} oversize | 39.690-39.706 {1.5625-1.5632} | 47.690-47.706 {1.8775-1.8782}
0.50 {0.02} oversize | 39.440-39.456 {1.5527-1.5533} | 47.440-47.456 {1.8677-1.8683}

  Maximum off-round
  0.10 mm {0.0039 in}

4. Inspect the main journal oil clearance using the following procedure.

  (1) Install the upper main bearing and crankshaft.
  (2) Position a plastigauge on the journals.
  (3) Install the lower main bearing and the lower cylinder block.
  (See Main Bearing Assembly Note.)
  (See Lower Cylinder Block Assembly Note.)
  (4) Remove the lower cylinder block.
  (See Lower Cylinder Block Disassembly Note.)
  (5) Measure the main journal oil clearance.

  • If it exceeds the maximum specification, replace the main bearing or grind the main bearing journal part and install the oversize bearing.

  Standard oil clearance
  0.014-0.038 mm {0.0006-0.0014 in}
  Maximum oil clearance
  0.084 mm {0.0033 in}
  Main bearing (mm {in})

  Bearing size | Bearing thickness (center thickness)
  --- | ---
  ZJ, ZY, Z6
  Standard | 2.511-2.529 {0.0989-0.0995}
  0.25 {0.01} oversize | 2.625-2.635 {0.1034-0.1037}
  0.50 {0.02} oversize | 2.750-2.760 {0.1083-0.1086}