1. |
Remove the timing belt, front case, flywheel,
cylinder head assembly and oil pan. For details, refer to the
respective chapters. |
2. |
Remove the rear plate and the rear oil
seal. |
3. |
Remove the connecting rod caps.
Put the main bearing caps in order of
their original position and direction for easier
reassembly. | |
4. |
Remove the main bearing caps and remove
crankshaft. Keep the bearings in order by cap
number. |
5. |
Remove the crankshaft position sensor
wheel. |
1. |
Remove the transmission and
clutch. |
1. |
Check the crankshaft journals and pins for
damage, uneven wear and crack. 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. : 57 mm (2.2440
in.)
Crankshaft pin O.D. : 45 mm (1.7717
in.)
Crankshaft journal, pin out-of-round and
taper
0.01 mm : (0.0004 in.) or
less
| |
MAIN BEARINGS AND CONNECTING ROD
BEARINGS
Visually inspect each
bearing for peeling, melting, seizure and improper contact. Replace the
defective bearings.
OIL CLEARANCE MEASUREMENT
1. |
Measure the diameter of crankshaft journal and
pin. |
2. |
Measure the diameter of crankshaft bore and
connecting rod bore. |
3. |
Measure the thickness of 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.
Main bearing oil clearance
:
0.028 ~ 0.046 mm (0.0011 - 0.0018
in.)
Connecting rod bearing oil clearance
:
(To set limits to new
parts)
0.024 ~ 0.042 mm (0.0009 ~ 0.0017
in.)
|


|
OIL SEAL
Check front and rear oil
seals for damage or worn lips. Replace any defective seal.
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 service limit, replace the
crankshaft bearing.
Standard value : 0.06 ~ 0.26 mm (0.0023 ~
0.010 in.)
Limit : 0.30 mm (0.0118
in.)
|

SENSOR WHEEL
1. |
Remove the crankshaft sensor
wheel. |
2. |
Check the crankshaft sensor wheel for damage,
crack and wear. Replace if
necessary. |
3. |
Check the clearance between crankshaft sensor
wheel and crank position sensor with a depth gauge.
Standard
value
Clearance between crankshaft sensor
wheel and crank position sensor :
0.5 ~ 1.1mm (0.020 ~
0.043in.)
|

•
|
Measure the depth of the top of
the sensor wheel tooth and the cylinder block mounting
surface. |
•
|
Measure the difference between
sensor length and
depth. |
•
|
Sensor length is the distance
between the end of sensor and inner point of contacting
face. | | |
1. |
Check the clutch disc contacting surface of
the flywheel for damage and wear. Replace the flywheel if
excessively damaged or worn. |
2. |
Check the clutch disc contacting surface of
the flywheel for runout.
Standard
value
Flywheel run-out : 0.1 mm (0.004
in.)
| |
3. |
Check the ring gear for damage, crack and
wear, and replace if necessary. |
1. |
Install the upper main bearing inserts in the
cylinder block.
When reusing the
main bearing, remember to install them by referring to the location
marks made when disassembling. |
2. |
Install the crankshaft. Apply engine oil to
the journals. |
3. |
Install bearing caps and tighten the 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 from 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 :
27 ~ 33 Nm (270 ~ 330 kg.cm, 20 ~
24lb.ft) + (60° ~ 65°)
Connecting rod cap bolt :
50 ~ 53 Nm (500 ~ 530 kg.cm, 37 ~ 39
lb.ft)
| |
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
Connecting rod end play :
0.10 ~ 0.25 mm (0.0039 ~ 0.0098
in.)
|

|
5. |
Using the special tool, crankshaft rear oil
seal installer (09231 - 21000) as shown, install the oil seal in the
crankshaft rear oil seal case.Press fit the oil seal being careful
not to align it wrong.

|
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. For further details, refer to the respective
chapters. |
Install the flywheel
assembly and tighten the bolts to the specified torque.
Tightening
torque
Flywheel bolt :
120 ~ 130 Nm (1200 ~ 1300 kg.cm, 90 ~ 96
lb.ft)
|