Crankshaft and CKP Pulse Plate Removal, Installation, and Inspection
9. Baffle Plate - Remove

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


11. Lower Block - Remove
1.
Remove the 8 mm bolts.
2.
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.
3.
Remove the lower block and the bearings. Keep all the bearings in order.

12. Crankshaft - Remove

13. CKP Pulse Plate - Remove

1. Crankshaft - Inspect
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 the main journal in two places. The difference between measurements on each journal must not be more than the service limit.
Main Journal Diameter
Standard (New):
No. 1, 2, 4, 5 Journals:
54.984?55.008 mm (2.16472?2.16566 in)
No. 3 journal:
54.976?55.000 mm (2.16441?2.16535 in)
Rod Journal Diameter
Standard (New):
47.976?48.000 mm (1.88882?1.88976 in)
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):
0.004 mm (0.00016 in) max.
Service Limit:
0.010 mm (0.00039 in)
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.

2. CKP Pulse Plate - Install

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 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.
4.
Apply new engine oil to the thrust washer surfaces. Install the thrust washers in the No. 4 journal of the engine block.

4. Lower Block - Install
1.
Apply liquid gasket to the engine block mating surface of the lower block and to the inside edge of the threaded bolt holes.
2.
Put the lower block on the engine block.
3.
Apply new engine oil to the threads of the bearing cap bolts. Torque the bearing cap bolts in sequence, to 35 N·m (3.6 kgf·m, 26 lbf·ft).
4.
Tighten the bearing cap bolts an additional 41 °.
5.
Torque the 8 mm bolts in sequence to 24 N·m (2.2 kgf·m, 16 lbf·ft).
NOTE:
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the lower block.

6. 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 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.
Tighten the connecting rod bolts to 5 N·m (0.5 kgf·m, 4 lbf·ft).
7.
Torque the connecting rod bolts to 40.7 N·m (4.15 kgf·m, 30.0 lbf·ft).
8.
Tighten the connecting rod bolts an additional 120 °.
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.

8. Baffle Plate - Install


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