Crankshaft and CKP Pulse Plate Removal, Installation, and Inspection
Special Tools Required
Image Description/Tool Number
310169.png Driver Handle, 15 x 135L 07749-0010000
10864669.png Oil Seal Driver Attachment, 92 mm 070AD-5R00100
2. Transmission - Remove


6. Cam Chain Drive Sprocket - Remove
1.
Remove the key (A) and the cam chain drive sprocket (B).
NOTE: Check the direction of the key. When the key is installed, install the key as same direction of the original one.

9. Oil Seal Case - Remove

10. Connecting Rod Cap and Bearing Half - Remove
NOTE: Keep all connecting rod caps and connecting rod bearings in order.


11. Main Bearing Cap - Remove
1.
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.
2.
Remove the main bearing caps (A) and the main bearings (B).
NOTE:
Check the installed position and direction of the main bearing caps.
When the main bearing caps are installed, install the main bearing caps as same location and direction of the original them.

12. Crankshaft - Remove
1.
Lift the crankshaft (A) out of the engine block, being careful not to damage the CKP pulse plate (B).
2.
Remove the thrust washers (C).

13. 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):
0.005 mm (0.00020 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 service limit.
Crankshaft Total Runout
Standard (New):
0.03 mm (0.0012 in) max.
Service Limit:
0.040 mm (0.00157 in)

2. CKP Pulse Plate - Install
1.
Apply new engine oil to the threads and flanges of CKP pulse plate mounting bolts.
2.
Install the CKP pulse plate (A) on the crankshaft (B).
NOTE:
Be careful not to damage the CKP pulse plate.
Position the mark (C) facing it out side and align the portion (D) on the CKP pulse plate and groove (E) on the crankshaft.

3. Crankshaft - Install
1.
Install the bearing halves in the engine block and the connecting rods.
2.
Apply a coat of new engine oil to the main bearings and the connecting rod bearings.
3.
Hold the crankshaft (A) so rod journal No. 2 and rod journal No. 3 are straight up, then lower the crankshaft into the engine block.
NOTE: Be careful not to damage the journals and the CKP pulse plate (B).

4. Thrust Washer - Install
1.
Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No. 4 journal of the engine block.

5. Main Bearing Cap - Install
1.
Apply new engine oil to the bearing cap bolts (A) threads and flanges.
2.
Install the bearing cap bolts to the main bearing cap (B).
3.
Set the bearing halves (C), the main bearing caps, and the bearing cap bolts in place. Then loosely tighten the bearing cap bolts.
NOTE:
Install the main bearing caps aligning the arrows (D) with the direction to the cam chain case.
When loosely tightening the bearing cap bolts, do not sit the bolts on the bearing caps.
4.
Lightly tap the main bearing caps with a plastic mallet until the main bearing caps sit on the engine block.

6. Bearing Cap Bolt - Tighten
1.
Tighten the bearing cap bolts, in the numbered sequence shown, to the specified torque.
Specified Torque:
30 N·m (3.1 kgf·m, 22 lbf·ft)
NOTE: Do not rotate the crankshaft during inspection.
2.
Tighten the bearing cap bolts an additional 40 °.

8. Connecting Rod Bolt - Inspect
1.
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?0.05 mm (0?0.0020 in)
3.
If the difference in diameter is out of specification, replace the connecting rod bolt.

9. Connecting Rod 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 cap.
3.
Install the connecting rod 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 cap.
5.
Install the connecting rod caps and the bolts finger-tight.
6.
Torque the connecting rod bolts to the specified torque.
Specified Torque:
13 N·m (1.3 kgf·m, 10 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.

10. Transmission End Crankshaft Oil Seal - Install
1.
Remove the transmission end crankshaft oil seal.
2.
Clean and dry the transmission end crankshaft oil seal housing.
3.
Apply a light coat of new engine oil to the lip of the new transmission end crankshaft oil seal.
4.
Use the driver handle, 15 x 135L and the oil seal driver attachment, 92 mm to drive a new transmission end crankshaft oil seal (A) squarely into the oil seal case.

11. Oil Seal Case - Install
1.
Apply liquid gasket to the engine block mating surface of the oil seal case, and to the inside edge of the threaded bolt holes.
2.
Install the oil seal case (A) with a new O-ring (B).

14. Cam Chain Drive Sprocket - Install
1.
Install the cam chain drive sprocket (A) and the key (B).

18. Transmission - Install