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
609804.png Bearing Driver Attachment, 28 x 30 mm 07946-1870100
4. Connecting Rod Cap and Bearing Half - Remove
NOTE: Keep all connecting rod caps and connecting rod bearings in order.


5. Crankshaft 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 crankshaft main bearing caps.

6. 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).

7. CKP Pulse Plate - Remove

1. Crankshaft - Inspect
Journal Diameter, 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 for damage.
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 main journal must not be more than the service limit.
Crankshaft Total Runout
Standard (New):
0.03 mm (0.0012 in) max.
Service Limit:
0.04 mm (0.0016 in)

1. Pilot Bearing/Crankshaft Pilot Bushing - Install
1.
Install the pirot bearing/crankshaft pilot bushing when replacing the crankshaft. Using the driver handle, 15 x 135L and the bearing driver attachment, 28 x 30 mm, to drive the pirot bearing/crankshaft pilot bushing squarely into the crankshaft to the specified installed height.

3. Crankshaft and CKP Pulse Plate - Install
1.
Apply new engine oil to the threads and flange of the CKP pulse plate mounting bolts.
2.
Install the CKP pulse plate (A) on the crankshaft (B).
3.
Hold the crankshaft so that rod journal No. 2 and rod journal No. 3 are straight up, and lower the crankshaft into the engine block.

4. Crankshaft - Install

5. 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.
2.
Install the main bearings and the main bearing caps, then torque the main bearing cap bolts to 30 N·m (3.1 kgf·m, 22 lbf·ft) in the proper sequence.
NOTE: Apply new engine oil to the bolt threads and flanges.
3.
Tighten the bearing cap bolts in the number sequence shown as the table below.
No. 1, 2, 4, and 5 journals:
22 °
No. 3 journal:
32 °

7. 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)

8. Connecting Rod Cap/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 bearing cap.
3.
Install the 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 bearing cap.
5.
Install the bearing caps and the bolts finger-tight.
6.
Torque the connecting rod bolts to 10 N·m (1.0 kgf·m, 7 lbf·ft).
7.
Tighten the connecting rod bolts an additional 90 °.


NOTE: The CKP pattern learn is required after this procedure.