1. |
Remove the timing belt train, 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.
Mark the main bearing caps to be able to
reassemble in the original position and
direction. | |
4. |
Remove the main bearing caps and remove the
crankshaft. Keep the bearings in order according to the cap
number. |
1. |
Check the crankshaft journals and pins for
damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective
parts. |
2. |
Inspect the crankshaft journal and pin for
out-of-round and taper.
Standard
value
Crankshaft journal O.D :
61.982 ~ 62.000mm (2.4402 ~
2.4409in.)
Crankshaft pin O.D :
47.982 ~ 48.000mm (1.8890 ~
1.8898in)
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|
Main Bearings and Connecting Rod
Bearings
Visually inspect each
bearing for peeling, melting, seizure and improper contact. Replace any
defective bearings.
Measuring Oil Clearance
Standard
value
Oil clearance
Crankshaft main bearing :
0.004 ~ 0.022mm (0.00015 ~
0.00087in.)
Connecting rod bearing :
0.018 ~ 0.036mm (0.00071 ~
0.00141in.)
Limit : 0.1mm (0.004 in.)
|

Plastic gauge Method
Plastic gauge may be
used to measure the clearance.
1. |
Remove oil, grease and any other dirt from the
bearings and journals. |
2. |
Cut the plastic gauge the same length as the
width of the bearing and place it in parallel with the journal,
avoiding the oil holes. |
3. |
Install the crankshaft, bearings and caps and
tighten them to the specified torques. During this operation, do not
turn the crankshaft. Remove the caps. Measure the width of the
plasticgauge at the widest part by usingthe scale printed on the
gauge package.
If the clearance exceeds the service limit,
the bearing should be replaced or an undersize bearing should be
used. When installing a new crankshaft,be sure to use standard size
bearings.
If the standard clearance can not be obtained
even after replacing the bearing, the journal and pin should be
ground to the undersize and a bearing of the corresponding size
should be installed.

|
Oil Seal
Check the front and rear
oil seals for damage or worn surfaces. Replace any seat that is
defective.
Drive Plate (A/T)
Replace distorted,
damaged, or cracked drive plates.
FLYWHEEL (M/T)
See EM
section.
Main Bearing
1. |
Install a grooved main bearing (upper bearing)
on the cylinder block side. |
2. |
Install a grooveless main bearing (lower
bearing) on the main bearing cap
side. |
3. |
Install the crankshaft. Apply engine oil to
journal and pin. |
4. |
Install the bearing caps with the arrow mark
directed toward the front of the engine. Cap number must be
correct. |
5. |
Tighten the cap bolts to the specified
torque.
Tightening
torque
Main bearing cap bolts
M8(9~16) : 13~19Nm (130~190kg.cm,
10~14lb.ft) + (90°~94°)
M10(1~8) : 27~33Nm (270~330kg.cm,
19.5~24 lb.ft) + (90°~94°)
|


|
6. |
Cap bolts should be tightened evenly in stages
4 to 5 increments before they are tightened to the specified
torque. |
7. |
Make certain that crankshaft turns freely and
check the end play of the crankshaft.
Crankshaft end
play
Standard : 0.070 ~ 0.250mm (0.0028 ~
0.0098in.)
Limit : 0.4mm
(0.016in.)
|

|
8. |
Using special tool(09231-33000), install the
rear oil seal in oil seal case. |
9. |
Apply sealant to the area shown in the
illustration. Install the oil seal case in the cylinder
block.
Tightening
torque
Oil seal case bolt :
10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9
lb.ft)
|


|
10. |
Tighten the rear plate to the specified
torque.
Tightening
torque
Rear plate : 10 ~ 12Nm (100 ~ 120kg.cm,
7 ~ 9 lb.ft)
| |
11. |
Tighten the drive plate and the adapter plate
(A/T).
Tightening
torque
Drive plate and adapter plate bolt
:
73 ~ 77Nm (730 ~ 770kg.cm, 53 ~ 56
lb.ft)
|

|
12. |
Tighten the fly wheel (M/T).
Tightening
torque
Fly wheel installation bolt
:
73 ~ 77Nm (730 ~ 770kg.cm, 53 ~
56lb.ft)
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|