Crankshaft and Piston Removal

Crankshaft and Piston Removal
1. Remove the engine assembly.
2. Remove the transmission.





3. Remove the CKP sensor (A) from the oil pump, then remove the timing belt drive pulley (B).
4. Remove the oil pan.





5. Remove the engine block end cover.





6. Remove the oil screen (A), baffle plate (B) and oil pump (C)





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





8. Remove the connecting rod caps after setting the crank pin at BDC for each cylinder. Remove the piston assembly by pushing on the connecting rod. Take care not to damage the crank journal or cylinder with the connecting rod.
9. Remove the bearing from the cap. Keep all caps/ bearings in order.
10. Remove the upper bearing halves from the connecting rods and set them aside with their respective caps.
11. After removing a piston/connecting rod assembly, reinstall the cap on the rod.
12. To avoid mix-up during reassembly, mark each piston/connecting rod assembly with its cylinder number.





13. Remove the bearing cap bolts (A) and bearing cap side bolts (B), then remove the bearing cap (C).





14. Lift the crankshaft (A) out of the cylinder block, being careful not to damage the journals.
15. Reinstall the main caps and bearings on the cylinder block in the proper order.

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 threads.
4. Support the crankshaft with a 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 that the service limit.

Out-of-Round and Taper





1. 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.
2. Measure taper at the edges 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)