Withdrawal
1. Remove the timing belt, front cover, wheel, cylinder head and oil pan.
2. Remove the rear plate and rear oil seal.
3. Remove the connecting rod caps.
Note. Mark the crankshaft main bearing caps so that they can be reinstalled in the same position.
4. Remove the main bearing caps and crankshaft. Arrange the liners according to the bearing cap numbers.
5. Remove the crankshaft position sensor wheel.
Examination
Crankshaft
1. Check the crankshaft main and connecting rod journals for damage, wear and cracks. Also check if the holes are clogged. Correct or replace any defective parts.
2. Check the crankshaft journals for ovality and taper.
Standard size:
- The outer diameter of the crankshaft journal is 50 mm
- The outer diameter of the crankpin is 45 mm
- Ovality and taper of the main and brass crankshaft journals - 0.01 mm or less
Main and connecting rod bearings
Visually inspect each bearing for delamination, melted areas, nicks, etc. Replace defective bearings.
Oil clearance measurement
Check the oil clearances by measuring the outside diameter of the crankshaft journals, crankpins and the inside diameter of the bearings. The gap is obtained by determining the difference between the measured inner and outer diameters.
Oil clearance of main journals:
- No. 1, 2, 4, 5 - 0.028-0.046 mm
- No. 3 - 0.034-0.052 mm
- Oil clearance of connecting rod journals - 0.024-0.042 mm
Measuring oil clearances with a plastic gauge
A plastic template can be used to measure gaps in the following way.
1. Remove oil, dirt and grease from bearings and crankshaft journals.
2. Cut a piece of plastic template equal to the width of the liner and place it along the axis of the neck away from the oil holes.
3. Fit the bearing shells and caps and tighten them to the correct torque. Do not rotate the crankshaft during this operation. Remove bearing caps. Using the scale printed on the template package, measure the thickness of the plastic template. If the gap exceeds the allowable value, the liner must be replaced or a reduced liner must be used. When installing a new crankshaft, use liners of nominal size. If the gap is not equal to the standard value even after changing the liner, the journals can be ground down to the recommended reduced size and the same size liner can be used.
Stuffing box
Check the front and rear oil seals for damage and lip wear. Replace defective oil seal.
Installation
1. Install the upper main bearing into the cylinder block. When reusing the main bearing during disassembly, make marks on it to facilitate its reinstallation.
2. Install the crankshaft. Apply engine oil to the journals.
3. Install bearing caps and tighten bolts to torque in sequence: center, #2, #4 front and rear caps. Cover bolts must be tightened evenly in 2-3 steps.
The covers must be installed with the arrows pointing towards the front of the engine. Make sure that the caps are positioned correctly according to their numbers.
Torque:
- Main bearing cap bolt - 55-60 Nm
- Connecting rod cap bolt - 35-38 Nm
4. Make sure the crankshaft rotates freely and has adequate play
- Axial play of the crankshaft - 0.05-0.175 mm
5. Install the crankshaft rear bearing seal. Use the special tool to install the crankshaft rear bearing seal (09231-21000), as shown. Press in the seal carefully.
6. Install the gasket and rear bearing oil seal housing.
7. Install back plate and tighten bolts.
8. Install the connecting rod caps.
9. Install the flywheel, front cover, oil pan and toothed belt.