Crankshaft
REMOVAL
1. Remove the timing belt, 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.
NOTE: Mark the main bearing caps to permit reassembly in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order by cap number.
5. Remove crankshaft position sensor wheel.
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 the crankshaft journals and pins.
[Standard dimension]
Crankshaft journal O.D. 57 mm (2.24 inch)
Crank pin O.D. 45 mm (1.77 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, overheating, seizure and improper contact. Replace the defective bearings.
Oil Clearance Measurement
To check the oil clearance, measure the outside diameter of the crankshaft journal and the crank pin and the inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured outside and inside diameters.
Oil clearance
Crankshaft main bearing 0.028 - 0.048 mm (0.0011 - 0.0018 inch)
Connecting rod bearing 0.024 - 0.044 mm (0.0009 - 0.0017 inch)
Limit 0.1 mm (0.004 inch)
Oil Clearance Measurement (Plastic-gauge Method)
Plastic-gauge may be used to measure the clearance.
1. Remove oil and grease and any other dirt from the bearings and journals.
2. Cut the plastic-gauge to the same length as the width of the crankshaft journal and place it in parallel with the journal, away from oil holes.
3. Install the bearings and caps and tighten them to the specified torque. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastic-gauge at the widest part by using a scale printed on the plastic-gauge package.
If the clearance exceeds the repair limit, the bearing should be replaced or an undersize bearing be used.
When installing a new crankshaft, be sure to use standard size bearings.
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 the front and rear oil seals for damage or worn lips. Replace any seal that is defective.
Bearing Caps
After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearings.
Standard value 0.05 - 0.18 mm (0.0020 - 00071 inch)
Limit 0.25 mm (0.0098 inch)
Drive Plate
Replace deformed, damage, or cracked drive plates.
Sensor Wheel
1. Remove the sensor wheel.
2. Check the sensor wheel for damage, cracks and wear, and replace if necessary.
3. Check the clearance between sensor wheel and crank position sensor with depth gage.
Clearance between sensor wheel and crank position sensor 0.5 - 1.1 mm (0.02 - 0.04 inch)
NOTE:
1. Measure the depth of the top of sensor wheel tooth and the outside of transaxle housing.
2. Measure the difference between sensor length and depth.
3. Sensor length is the distance between the end of sensor and inner point of contacting face.
INSTALLATION
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 corrected.
Tightening torque
Main bearing cap bolt 27 - 33 Nm (270 - 330 kg.cm, 20 - 24 ft. lbs.) + (60° - 65°)
Connecting rod cap bolt 50 - 53 Nm (500 - 530 kg.cm, 37 - 39 ft. lbs.)
4. Make certain that the crankshaft/urns freely and has the proper clearance while moving the crankshaft back and forth.
Crankshaft end play 0.06 - 0.26 mm (0.002 - 0.010 inch)
5. Install the oil seal in the crankshaft rear oil seal case. Use Special Tool, Crankshaft Rear Oil Seal Installer (09231-11000) as shown. Press fit the oil seal all the way in, 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.