Connecting Rod Bearing Cap and Bearing Half - Remove
NOTE: Keep all connecting rod bearing caps and connecting rod bearings in order.
12.
Lower Block - Remove
1.
Remove the 8 mm bolts in the sequence shown.
2.
Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
3.
Using a flat blade screwdriver, separate the lower block from the engine block in the places shown.
4.
Remove the lower block and the bearings. Keep all the bearings in order.
13.
Crankshaft - Remove
1.
Lift the crankshaft (A) out of the engine block, being careful not to damage the CKP pulse plate (B).
14.
CKP Pulse Plate - Remove
1.
Crankshaft - Inspect
Out-of-Round and Taper
1.
Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
2.
Check the keyway slot and the threaded holes.
3.
Measure the out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not be more than the service limit.
Journal Out-of-Round
Standard (New):
0.004 mm (0.00016 in) max.
Service Limit:
0.010 mm (0.00039 in)
4.
Measure the taper at the edges of each rod and the main journal. The difference between measurements on each journal must not be more than the service limit.
Journal Taper
Standard (New):
0.005 mm (0.00020 in) max.
Service Limit:
0.010 mm (0.00039 in)
Straightness
5.
Place the V-blocks on a flat surface.
6.
Check the total runout with the crankshaft supported on V-blocks.
7.
Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the standard.
Crankshaft Total Runout
Standard (New):
0.03 mm (0.0012 in) max.
1.
Crankshaft End Bushing - Install (M/T)
1.
Install the crankshaft end bushing when replacing the crankshaft. Using the driver handle, 15 x 135L and the bearing driver attachment, 24 x 26 mm, to drive the crankshaft end bushing squarely into the crankshaft to the specified installed height.
Measure the diameter of each connecting rod bolt at point A and point B.
2.
Calculate the difference in diameter between point A and point B.
Point A?Point B = Difference in Diameter
Difference in Diameter
Specification:
0?0.1 mm (0?0.004 in)
3.
If the difference in diameter is out of specification, replace the connecting rod bolt.
8.
Connecting Rod Bearing Cap and Bearing Half - Install
1.
Apply new engine oil to the threads of the connecting rod bolts.
2.
Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the connecting rod bearing cap.
3.
Install the connecting rod bearing caps and the bolts finger-tight.
4.
Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the connecting rod bearing cap.
5.
Install the connecting rod bearing caps and the bolts finger-tight.
6.
Torque the connecting rod bolts to 20 N·m (2.0 kgf·m, 15 lbf·ft).
7.
Tighten the connecting rod bolts an additional 90 °.
NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle.
