Crankshaft: Service and Repair

CRANKSHAFT

- Tools Required
- KM-412 Engine Overhaul Stand
- J-42492 Timing Belt Adjuster
- KM-470-B Angular Torque Gauge
- J-36792 or KM-635 Crankshaft Rear Oil Seal Installer

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

Disassembly Procedure
1. Remove the engine.





2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel 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 upper and lower front timing belt cover bolts.
7. Remove the upper and lower front timing belt cover.





8. Remove the power steering pump mounting bolts, if equipped.
9. Remove the power steering pump, if equipped.





10. Slightly loosen the coolant pump retaining bolts.





11. Rotate the coolant pump using the timing belt adjuster J-42942 to remove the tension from the timing belt.
12. Remove the timing belt.
13. Disconnect the crankcase ventilation tubes from the valve cover.
14. Remove the spark plug cover bolts.
15. Remove the spark plug cover.
16. Disconnect the ignition wires from the spark plugs.





17. Remove the valve cover nuts.
18. Remove the valve cover washers.
19. Remove the valve cover and the valve cover gasket.

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





20. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
21. Remove the intake camshaft gear.
22. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt.
23. Remove the exhaust camshaft gear.





24. Remove the timing bed automatic tensioner bolts.
25. Remove the timing belt automatic tensioner.
26. Remove the timing belt idler pulley bolt.
27. Remove the timing belt idler pulley.





28. Remove the crankshaft timing belt gear.
29. Remove the rear timing belt cover bolts.
30. Remove the rear timing belt cover.





31. Rotate the engine on the engine overhaul stand KM-412.
32. Remove the oil pan retaining bolts.
33. Remove the oil pan.





34. Remove the oil pickup tube bolts.
35. Remove the oil pickup tube.





36. Remove the oil pump retaining bolts.
37. Remove the oil pump.
38. Mark the order of the connecting rod bearing caps.





39. Remove the connecting rod bearing cap bolts for all of the pistons.
40. Remove the connecting rod bearing caps and the lower connecting rod bearings.
41. Remove the upper connecting rod bearings.





42. Mark the order of the crankshaft bearing caps.
43. Remove the crankshaft bearing cap bolts.
44. Remove the crankshaft bearing caps and the lower crankshaft bearings.
45. Remove the crankshaft.
46. Remove the upper crankshaft bearings.
47. Clean any parts that need it.

Assembly Procedure
1. Coat the crankshaft bearings with engine oil.





2. Install the upper crankshaft bearings in the engine block.
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.





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

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 which is available in different tolerance ranges.





9. Cut the plastic gauging threads to the length of the bearing width. Lay them 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 (37 ft. lbs.) plus 45 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.
13. Inspect the bearing clearance for permissible tolerance ranges.
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 50 Nm (37 ft. lbs.) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the crankshaft bearings 45 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 plastic gauging.





18. Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them 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 25 Nm (18 ft. lbs.) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod bearing cap bolts to 30 degrees plus 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.
22. Inspect the bearing clearance for permissible tolerance ranges.
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 25 Nm (18 ft. lbs.) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod cap bolts to 30 degrees plus 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 oil pump pickup tube.





28. Install the oil pump pickup tube bolts.
- Tighten the oil pump/pickup tube bolts to 10 Nm (89 inch lbs.).
29. Install the oil pan gasket to the oil pan.





30. Install the oil pan.

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

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





32. Rotate the engine on the engine overhaul stand KM-412.





33. Install the rear timing belt cover.
34. Install the rear timing belt cover bolts.
- Tighten the rear timing belt cover bolts to 10 Nm (89 inch lbs.).
35. Install the crankshaft timing belt gear.
36. Install the timing belt automatic tensioner.





37. Install the timing belt automatic tensioner bolts.
- Tighten the timing belt automatic tensioner bolts to 25 Nm (18 ft. lbs.).
38. Install the timing belt idler pulley.
39. Install the timing belt idler pulley bolt.
- Tighten the timing belt idler pulley bolt to 40 Nm (30 ft. lbs.).

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

40. Install the intake camshaft gear.





41. Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.
- Tighten the intake camshaft gear bolt to 67.5 Nm (49 ft. lbs.)
42. Install the exhaust camshaft gear.
43. Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.
- Tighten the exhaust camshaft bolt to 67.5 Nm (49 ft. lbs.).
44. Install the timing belt.
45. Adjust the timing belt tension.
46. 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.
47. Install the valve cover and the valve cover gasket.
48. Install the valve cover washers.





49. Install the valve cover nuts.
- Tighten the valve cover nuts to 9 Nm (80 inch lbs.).
50. Connect the ignition wires to the spark plugs.
51. Install the spark plug cover.
52. Install the spark plug cover bolts.
- Tighten the spark plug cover bolts to 3 Nm (27 inch lbs.).
53. Connect the crankcase ventilation tube to the valve cover.





54. Install the upper and lower front timing belt cover.
55. Install the upper and lower front timing belt cover bolts.
- Tighten the upper and lower front timing belt cover bolts to 10 Nm (89 inch lbs.).
56. Install the power steering pump, if equipped.
57. Install the power steering pump mounting bolts.
- Tighten the power steering pump mounting bolts to 25 Nm (18 ft. lbs.).
58. Install the engine lifting device.





59. Remove the engine from the engine overhaul stand KM-412.





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





62. Install the flywheel or the flexible plate bolts.
- Tighten the flywheel bolts to 35 Nm (25 ft. lbs.). Use the angular torque gauge KM-470-B to tighten the flywheel bolts 30 degrees plus 15 degrees.
- For the manual transaxle, tighten the flexible plate bolts to 60 Nm (44 ft. lbs.).
63. Install the engine.