Crankshaft and Cylinder Block
CRANKSHAFT AND CYLINDER BLOCKREMOVAL AND INSTALLATION
Removal Steps 1-9:
REMOVAL SERVICE POINT
[A] CRANKSHAFT REMOVAL
After removing the crankshaft with the crankshaft sensing ring attached, temporarily place it on a V-block to prevent teeth of the sensing ring from deforming.
NOTE: If a tooth bends, be sure to replace the crankshaft sensing ring with a new one.
INSTALLATION SERVICE POINTS
[A] CRANKSHAFT SENSING RING INSTALLATION
Tighten crankshaft sensing ring bolts to the specified torque in the tightening order shown in the illustration.
Specified torque: 11 ± 1 Nm (98 ± 8 in-lb)
[B] THRUST BEARING INSTALLATION
1. Install the thrust bearing on the No. 3 bearing on the cylinder block side. Application of engine oil makes the installation easier.
2. Install the thrust bearing so that the grooved side is on the crankshaft weight side.
[C] CRANKSHAFT BEARING UPPER INSTALLATION
1. When replacing the crankshaft bearing upper, select a bearing with the size corresponding to the cylinder block journal diameter in the table below.
2. The crankshaft bearing upper has an identification colour at the illustrated position.
3. Install the selected crankshaft bearing upper.
[D] CRANKSHAFT BEARING LOWER INSTALLATION
1. When replacing the crankshaft bearing lower, select a bearing with the size corresponding to the crankshaft journal diameter in the table below.
2. The crankshaft bearing lower has an identification colour at the illustrated position.
3. Install the selected crankshaft bearing lower.
[E] CRANKSHAFT BEARING CAP / CRANKSHAFT BEARING CAP BOLT INSTALLATION
1. Install the crankshaft bearing cap with reference to the identification mark as illustrated.
2. Before using the crankshaft bearing cap bolt again, carry out the check according to the following procedure:
1) Measure the 2 points on the outside diameter of thread as shown in the illustration.
2) When the difference between the measured outside diameters is beyond the limit value, replace the crankshaft bearing cap bolt.
Limit value
M10: 0.15 mm (0.006 inch)
M8: 0.10 mm (0.004 inch)
3. Apply engine oil to the threaded portion and seat surface of the bolt.
4. Tighten crankshaft bearing cap bolts to the specified torque according to the tightening order.
Specified torque
M10: 37.2 ± 2.0 Nm (27 ± 1 ft-lb)
M8: 9.0 ± 2.0 Nm (80 ± 17 in-lb)
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap 90 degrees from the paint mark made on the bolt, in the direction of tightening the bolt.
CAUTION:
^ When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
^ When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
7. Turn each bolt 90 degrees in the tightening sequence specified in step 1, and make sure that the paint marks on the bolt and cap are aligned.
8. Check end play of the crankshaft after installing the crankshaft bearing cap. If the end play exceeds the limit, replace the thrust bearing.
Standard value: 0.05 -0.25 mm (0.002 -0.010 inch)
Limit: 0.4 mm (0.02 inch)
INSPECTION
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE METHOD)
Oil clearance can be easily measured by using a "plastigage." When using a "plastigage," perform measurement in the following procedure.
1. Fully wipe oil off the outside diameter of the crankshaft and inside diameter of the bearing.
2. Assemble the crankshaft.
3. Place a plastigage in length equal to the bearing width on the journal shaft straight in alignment with the shaft center.
4. Carefully install the bearing cap and tighten the bolt according to the main point of installation [B].
5. Remove the bolt, and then carefully remove the crankshaft bearing cap.
6. Measure the crushed plastigage width (area most widely crushed) using a scale printed on the plastigage bag.
Standard value:
No. 1, 2, 4, 5: 0.039 -0.065 mm (0.0015 -0.0026 inch)
No. 3: 0.051 -0.077 mm (0.0020 -0.0030 inch)
Limit: 0.10 mm (0.004 inch)
CYLINDER BLOCK
1. Visually check the cylinder block for scratch, rust and corrosion. Use a flaw detecting agent to check for cracks. If it is found faulty, repair or replace it.
2. Measure distortion on the top surface of the cylinder block using a straight edge and thickness gauge.
If distortion exceeds the limit, grind and repair it.
A gasket or the like must not be adhered to the top surface of the cylinder block during measurement.
Distortion on bottom
Standard value: Within 0.05 mm (0.002 inch)
Limit: 0.2 mm (0.01 inch)
Grinding limit: 0.2 mm (0.01 inch)
3. Check the cylinder bore for scoring or seizure. If faulty, correct (boring) or replace.
4. Measure the bore and cylindricity of the cylinder using a cylinder gauge.
If the cylinder is excessively worn, repair the cylinder and replace the piston and piston rings.
Measuring points are as shown in the illustration.
Standard value
Cylinder bore: 86 mm (3.4 inches)
Cylindricity: 0.010 mm or less (0.0004 inch)
BORING CYLINDERS
1. Oversize pistons should be based on the largest bore cylinder.
2. In case of 0.25 mm (0.010 inch) oversized piston, a hole shall be bored through the cylinder block so that the clearance can have the standard value. The standard measuring point for the outside piston diameter is at shown in the illustration.
3. Based on the measured piston outside diameter (0.D.), calculate the boring finish dimension.
Boring finish dimension = Piston 0.D. + 0.03 -0.05 mm (0.001 -0.002 inch) [Clearance between piston 0.D. and cylinder] -0.02 mm (0.001 inch) [honing margin]
4. Bore each cylinders to the calculated boring finish dimension.
CAUTION:
To prevent distortion caused by heat increased during boring, bore the cylinders in the following order: No.2, No.1, No.3.
5. Hone the cylinders to the final finish dimension (piston 0.D. + piston-to-cylinder clearance).
6. Check the clearance between the pistons and cylinders.
Standard value: 0.03 -0.05 mm (0.001 -0.002 inch)
NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.