Crankshaft: Service and Repair

Notice: Take extreme care to prevent any scratches, nicks, or damage to the camshafts.

Disassembly Procedure
1. Remove the engine. Refer to Engine; Service and Repair.





2. Remove the "flexible plate bolts.
3. Remove the or the flexible plate.





4. Remove the crankshaft rear oil seal.
5. Mount the engine assembly on the engine overhaul stand KM-412.





6. Remove the front timing belt cover bolts.
7. Remove the front timing belt cover.
8. Remove the crankshaft pulley bolts.
9. Remove the crankshaft pulley.





10. Loosen the timing belt automatic tensioner bolt.
11. Rotate the timing belt automatic tensioner hex-key clockwise to release the tension.
12. Remove the timing belt idler pulley bolt and nut.
13. Remove the timing belt idler pulleys.
14. Remove the timing belt.
15. Remove the engine mount retaining bolts.
16. Remove the engine mount.
17. Disconnect the crankcase breather tubes from the valve cover.
18. Remove the spark plug cover bolts.
19. Remove the spark plug cover.
20. Disconnect the ignition wires from the spark plugs.





21. Remove the valve cover bolts.
22. Remove the valve cover washers.
23. Remove the valve cover and the valve cover gasket.

Notice: Take extreme care to prevent any scratches, nicks or damage to the camshafts.





24. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
25. Remove the intake camshaft gear.
26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
27. Remove the exhaust camshaft gear.





28. Remove the crankshaft timing belt gear.





29. Remove the rear timing belt cover bolts and cover.





30. Rotate the engine on the engine overhaul stand KM-412.
31. Remove the oil pan retaining bolts.
32. Remove the oil pan.
33. Remove the oil pump/pickup tube bolts.
34. Remove the oil pump/pickup tube.





35. Remove the lower block support bracket/splash shield bolts.
36. Remove the splash shield.
37. Remove the lower block support bracket bolts.
38. Remove the lower block support bracket.





39. Remove the oil pump retaining bolts.
40. Remove the oil pump.





41. Mark the order of the connecting rod bearing caps.
42. Remove the connecting rod bearing cap bolts for all of the pistons.
43. Remove the connecting rod bearing caps and the lower connecting rod bearings.





44. Mark the order of the crankshaft bearing caps.
45. Remove the crankshaft bearing cap bolts.
46. Remove the crankshaft bearing caps and the lower crankshaft bearings.
47. Remove the crankshaft.
48. Clean any necessary parts.

Assembly Procedure





1. Coat the crankshaft bearings with engine oil.
2. If replacing the crankshaft, transfer the pulse pick-up sensor disc to the new crankshaft.
3. Install the crankshaft.
4. Install the lower crankshaft bearings in the bearing caps.
5. Inspect the crankshaft end play with the crankshaft bearings installed.





6. Check for permissible crankshaft end play. Refer to Crankshaft, Engine; Specifications.





7. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to Crankshaft, Engine; Specifications.

Important: Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.

8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).





9. Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
10. Install the crankshaft bearing caps and the bolts.
Tighten the crankshaft bearing cap bolts to 50 Nm (26 ft. lbs.). Use the angular torque gauge, KM-470-B, to tighten the crankshaft bearings + 45 degrees + another 15 degrees.
11. Remove the crankshaft bearing cap bolts and the caps.





12. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
13. Inspect the bearing clearance for permissible tolerance ranges. Refer to Crankshaft, Engine; Specifications.
14. Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine block.





16. Tighten the crankshaft bearing caps using new bolts.
Tighten the crankshaft bearing cap bolts to 15 Nm (26 ft. lbs.). Use the angular torque gauge, KM-470-B, to tighten the crankshaft bearings + 45 degrees + another 15 degrees.

Important: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear when the connecting rod bearing caps are removed.

17. Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).





18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
19. Install the connecting rod bearing caps.
Tighten the connecting rod bearing cap bolts to 35 Nm (26 ft. lbs.). Use the angular torque gauge KM-470-B to tighten the connecting rod bearing cap bolts to + 45 degrees plus one turn of 15 degrees.
20. Remove the connecting rod bearing caps.





21. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
22. Inspect the bearing clearance for permissible tolerance ranges. Refer to Connecting Rod, Engine; Specifications.
23. Install the connecting rod bearing caps to the connecting rods.





24. Tighten the connecting rod bearing caps using new bolts.
Tighten the connecting rod bearing cap bolts to 35 Nm (26 ft. lbs.). Use the angular torque gauge, KM-470-B, to tighten the connecting rod cap bolts to +45 degrees plus one turn of 15 degrees.
25. Install the oil pump.





26. Install the oil pump retaining bolts.
Tighten the oil pump retaining bolts to 10 Nm (89 inch lbs.).





27. Install the lower block support bracket and bolts.
Tighten the lower block support bolts to 35 Nm (26 ft. lbs.).
28. Install the lower block support bracket splash shield and bolts.
Tighten the lower block support bracket and splash shield bolts to 35 Nm (26 ft. lbs.).
29. Install the oil pump/pick-up tube.
30. Install the oil pump/pick-up tube bolts.
Tighten the oil pump/pick-up tube bolts to 10 Nm (89 inch lbs.).
31. Install the oil pan gasket to the oil pan.
32. Install the oil pan.

Important: Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan.





33. Install the oil pan retaining bolts.
Tighten the oil pan retaining bolts to 10 Nm (89 inch lbs.).





34. Rotate the engine on the engine overhaul stand KM-412.
35. Install the rear timing belt cover.
36. Install the rear timing belt cover bolts.
Tighten the rear timing belt cover bolts to 8 Nm (71 inch lbs.).





37. Install the crankshaft timing belt drive gear and bolt.
Tighten the crankshaft timing belt drive gear bolt to 130 Nm (96 ft. lbs.) plus 40° to 50° using the torque angular gauge KM-470-6.
38. Install the engine mount and retaining bolts.
Tighten the engine mount retaining bolts to 60 Nm (44 ft. lbs.).





39. Install the timing belt automatic tensioner.
40. Install the timing belt automatic tensioner bolts.
Tighten the timing belt automatic tensioner bolts to 25 Nm (18 ft. lbs.).
41. Install the timing belt idler pulley.
42. Install the timing belt idler pulley bolt and nut.
Tighten the timing belt idler pulley bolt to 25 Nm (18 ft. lbs.).
Tighten the timing belt idler pulley nut to 25 Nm (18 ft. lbs.).

Notice: Take extreme care to prevent any scratches, nicks or damage to the camshafts.

43. Install the intake camshaft gear.





44. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.
Tighten the intake camshaft gear bolt to 50 Nm (37 ft. lbs.).
45. Install the exhaust camshaft gear.
46. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.
Tighten the exhaust camshaft gear bolt to 50 Nm (37 ft. lbs.). Using the angular torque gauge KM-470-13, tighten the intake and the exhaust camshaft gear bolts another 60° plus 15°.
47. Install the timing belt.
48. Adjust the timing belt tension. Refer to Timing Belt; Adjustments.
49. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear valve cover to cylinder head seal.
50. Install the valve cover and the valve cover gasket.
51. Install the valve cover washers.





52. Install the valve cover bolts.
Tighten the valve cover bolts to 8 Nm (71 inch lbs.).
53. Connect the ignition wires to the spark plugs.
54. Install the spark plug cover.
55. Install the spark plug cover bolts.
Tighten the spark plug cover bolts to 3 Nm (27 inch lbs.).
56. Connect the crankcase breather tube to the valve cover.
57. Install the front timing belt cover.





58. Install the front timing belt cover bolts.
Tighten the front timing belt cover bolts to 6 Nm (53 inch lbs.).
59. Install the engine lifting device.
60. Remove the engine from the engine overhaul stand KM-412.





61. Install a new crankshaft rear oil seal using installer J-36972 (or KM-635).
62. Install the flywheel or flexible plate.





63. Install the flywheel or the flexible plate bolts.
Tighten the flywheel bolts to 65 Nm (48 ft. lbs.). Use the angular torque gauge KM-470-B to tighten the flywheel bolts to 30° plus 15°. For the automatic transmission, tighten the flexible plate bolts to 65 Nm (48 ft. lbs.).
64. Install the engine. Refer to "Engine; Service and Repari.