Crankshaft

CRANKSHAFT INSPECTION AND REPAIR
1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crankshaft.

2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter:
STD: 63.985 - 64.00 mm (2.5191 - 2.5197 in.)
U/S 0.25: 63.745 - 63.755 mm (2.5096 - 2.5100 in.)
Crank pin diameter:
STD: 54.987 - 55.000 mm (2.1648 - 2.1654 in.)
U/S 0.25: 54.745 - 54.755 mm (2.1553 - 2.1557 in.)
If the diameter is not as specified, check the oil clearance.
(b) Check each main journal and crank pin for taper and out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm (0.0008 in.)
If the taper or out-of-round is greater than maximum, grind or replace the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 2).
Install new main journal and/or crank pin undersized bearings.

CRANKSHAFT OIL SEALS REPLACEMENT

HINT: There are two methods (A and B) to replace the oil seal which are as follows:

1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If oil pump is removed from cylinder block:
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. SST 09309-37010
(c) Apply MP grease to the oil seal lip.

B. If oil pump is installed to the cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge. SST 09309-37010

2. REPLACE CRANKSHAFT REAR OIL SEAL
A. If rear oil seal retainer is removed from cylinder block:
(a) Using screwdriver and hammer, tap out the oil seal.

(b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge. SST 09223-56010
(c) Apply MP grease to the oil seal lip.

B. If rear oil seal retainer is installed to cylinder block:
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

(c) Apply MP grease to a new oil seal lip.
(d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010

PISTON AND CONNECTING ROD ASSEMBLY
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring on one side of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

(b) Gradually heat the piston to 60°C (140°F).

(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. Connecting rod front (mold) mark: A1, B6, 1B, 8A, C3 or etc.

(e) Install a new snap ring on the other side of the piston pin hole.

HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

2. INSTALL PISTON RINGS
(a) Install the oil ring expander and two side rails by hand.

(b) Using a piston ring expander, install the two compression rings with the code mark facing upward.
Code mark:
No.1: T or 1R
No.2: T2 or 2R

3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting rod cap.