Crankshaft

DISASSEMBLY
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.
4. Remove the main bearing caps and remove the crankshaft.
5. Remove the crankshaft position sensor wheel.

CAUTION: Mark the main bearing caps to permit reassembly in the original position and direction.

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 the crankshaft journal for taper and out-of-round.
Standard value
Crankshaft journal O.D: 50 mm (1.9685 inch)
Crankshaft pin O.D: 45 mm (1.7717 inch)
Crankshaft journal, pin out-of-roundness and taper 0.005 mm (0.0002 inch) or less

MAIN BEARINGS AND CONNECTING ROD BEARINGS
1. Visually inspect each bearing for peeling, melting, seizure, and improper contact. Replace the defective bearings.

OIL CLEARANCE MEASUREMENT
1. Measure the diameter of the crankshaft journal and pin.
2. Measure the diameter of the crankshaft bore and connecting rod bore.
3. Measure the thickness of the crankshaft bearing and connecting rod bearing.
4. Measure the clearance by the value that subtract the diameter of journal and pin and the thickness of bearing from the diameter of bore.
Connecting rod bearing oil clearance 0.018 - 0.036 mm (0.0007 - 0.0014 inch)
Crankshaft main bearing oil clearance
NO.1, 2, 4, 5: 0.022 - 0.040 mm (0.0009 - 0.0018 inch)
NO.3: 0.028 - 0.046 mm (0.0011 - 0.0018 inch)

OIL SEAL
1. Check front and rear oil seals for damage or wear. Replace any seal that is defective.

CRANKSHAFT 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 the sensor wheel and the crank position sensor with a depth gage.
Standard value
Clearance between sensor wheel and crank position sensor: 0.5 - 1.1 mm (0.020 - 0.043 inch)

NOTE:
1. Measure the depth of the top of sensor wheel tooth and the cylinder block mounting block.
2. Measure the difference between sensor length and depth.
3. Sensor length is the distance between the end of the sensor and the inner point of the contacting face.

REASSEMBLY
1. Install the upper main bearing inserts in the cylinder block.
When rousing 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 following sequence; 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 correct.
Tightening torque
Main bearing cap bolt 55 - 60 Nm (550 - 600 kg.cm, 41 - 44 ft. lbs.)
Connecting rod cap bolt: 32 - 35 Nm (320 - 350 kg.cm, 24 - 26 ft. lbs.)
4. Make certain that the crankshaft turns freely and has the proper clearance between the center main bearing thrust flange and the connecting rod big end bearing.
Standard value
Crankshaft end play 0.05 - 0.175 mm (0.0019 - 0.0068 inch)





5. Install the oil seal in the crankshaft rear oil seal case. Use the Special Tool, Crankshaft Rear Oil Seal Installer (09231-21000) as shown. Press fit the oil seal all the way in, being careful not to misalign it.
6. Install the rear plate and tighten the bolts.
7. Install the connecting rod caps.
8. Install the flywheel, front case, oil pan and timing belt.