Crankshaft and Piston Removal

Crankshaft and Piston Removal
1. Remove the engine assembly.
2. Remove the transmission:
^ Manual transmission.
^ Automatic transmission.
3. Remove the oil pan.
4. Remove the oil pump.
5. Remove the cylinder head.





6. Remove the baffle plate.





7. Remove the 8 mm bolts.





8. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time: repeat the sequence until all bolts are loosened.





9. Remove the lower block and bearings. Keep all bearings in order.
10. Remove the rod caps/bearings. Keep all caps bearings in order.





11. Lift the crankshaft out of the engine, being careful not to damage the journals.
12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.





13. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.





14. Use the wooden handle of a hammer (A) to drive out the pistons (B).
15. Reinstall the lower block and bearings on the engine in the proper order.
16. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
17. To avoid mix-up on reassembly, mark each piston/ connecting rod assembly with its cylinder number.

NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.

Crankshaft Inspection
Straightness
1. Remove the crankshaft from the engine block.
2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
3. Check the keyway and thread; repair or replace it if necessary.
4. Support the crankshaft with V-blocks.





5. Measure runout on all main journals to make sure the crank is not bent. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit.
Crankshaft Total Indicator Runout:
K20A3 engine
Standard (New): 0.03 mm (0.0012 inch) maximum
Service Limit: 0.04 mm (0.0016 inch)
K20A2 engine
Standard (New): 0.02 mm (0.0008 inch) maximum
Service Limit: 0.03 mm (0.0012 inch)

Out-of-Round and Taper





6. Measure 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 (0.0002 inch) maximum
Service Limit: 0.010 mm (0.0004 inch)
7. Measure taper at the edge of each rod and main journal. The difference between measurements on each journal must not be more than the service limit.
Journal Taper:
Standard (New): 0.005 mm (0.0002 inch) maximum
Service Limit: 0.010 mm (0.0004 inch)