Pic. 2.113. Crankshaft and flywheel
Disassembly
Remove the timing belt, front cover, flywheel, cylinder head and oil pan.
Remove the cylinder block rear plate and crankshaft rear oil seal.
Remove the connecting rod caps and connecting rod bearing shells.
Note. For correct subsequent installation, position the removed parts (connecting rod caps, connecting rod and main bearing shells) in order of their respective cylinder numbers and installation orientation.
Remove the main bearing cap assembly and crankshaft. Position the main bearing shells in order of their respective cylinder numbers.
Checking the crankshaft
Check the crankshaft main and connecting rod journals for damage (snags and grips), excessive wear and cracks. Clean the shaft oil channels. Repair or replace crankshaft if necessary.
Pic. 2.114. Scheme for measuring the taper and out-of-roundness of the main and connecting rod journals of the crankshaft
Check the taper and out-of-roundness of the main and connecting rod journals of the crankshaft (pic. 2.114).
The nominal value of the measured diameters is given below.
Main journal diameter: 56.982–57.000 mm.
Crankpin diameter: 44.980–45.000 mm.
Taper and out-of-roundness of main journals and crankpins: 0.01 mm or less.
Checking the liners of main and connecting rod bearings
Visually inspect the surface condition of each liner (flaking of the friction layer, uneven contact, risks, scoring, etc.). Replace defective earbuds.
Bearing clearance measurement
Pic. 2.115. Scheme for measuring the internal diameters of the holes for the main bearings in the bed of the crankshaft with a caliper
Measure the diameter of the main and connecting rod journals of the crankshaft. Measure the inner diameters of the main bearing holes in the crankshaft bed (in the cylinder block and bearing cap) and holes for connecting rod bearings (in the lower head and connecting rod cap). Measure the thickness of the connecting rod and main bearing shells. Calculate the clearance in the bearings from the results of the measurements (subtract from the inner diameter of the bearing hole the value of the diameter of the shaft journal and two values of the thickness of the bearing shell) (pic. 2.115).
Main bearing clearance:
- Necks No. 1,2,4,5 - 0.018–0.036 mm;
- Neck No. 3 - 0.024–0.042 mm.
Connecting rod bearing clearance: 0.015–0.048 mm.
Limit clearance: 0.1 mm.
Measuring bearing clearance with a plastic gauge
Determining the clearance in the crankshaft main bearings using the plastic gauge method is described below.
Remove oil, grease or other contaminants from the shaft journals. Wash and dry the bearing shells.
Pic. 2.116. Plastic caliber stacking
Cut the plastic gauge into pieces equal in width to the shaft journals. Lay the gauges on the necks along the axis of the shaft (do not put the gauge on the oil supply holes) (pic. 2.116).
Install the bearing shells, crankshaft and main bearing cap assembly. Tighten the cover bolts to the specified tightening torque. Do not rotate the crankshaft. Remove the cover block. Measure the maximum width of the flattened part of the gauge using the scale on the gauge envelope. Determine bearing clearance. Repair or replace crankshaft or bearing shells as needed. If the gap cannot be corrected by replacing the bearing, regrind the shaft journals to the repair size with the corresponding replacement of the bearings.
Checking crankshaft oil seals
Check the front and rear crankshaft oil seals for damage or wear on the sealing lips. In the presence of defects replace an epiploon.
Checking bearing caps
Pic. 2.117. Measurement of crankshaft end play
After installing the main bearing cap assembly, check that the crankshaft rotates smoothly and that the crankshaft axial clearance is correct. If the axial clearance exceeds the maximum allowable value, replace the thrust half-rings of the bearing and / or bearing shells (pic. 2.117).
Nominal value: 0.05 - 0.25 mm.
Checking the automatic transmission drive plate
Replace warped or cracked plate.
Flywheel check
Check the flatness of the flywheel for installing the clutch drive plate. If there are deep scratches or severe wear, replace the flywheel.
Check flywheel runout.
Limit runout: 0.13 mm.
Check the condition of the flywheel teeth. Replace crown if necessary.
Assembly
Install the upper main bearing shells into the crankshaft bed on the cylinder block. The top bearings have an oil distribution groove.
Install the bottom bushings (without grooves) in the bed of the main bearing cap block.
Pic. 2.118. Center neck inserts
Center neck inserts (with thrust bearing) no oil distribution grooves (pic. 2.118).
Pic. 2.119. Crankshaft Installation Diagram
Apply engine oil to the crankshaft journals. Install the crankshaft (pic. 2.119).
Install the lower shells and the main bearing cap assembly with the mark toward the front of the engine.
Tighten the cover bolts to the rated torque.
Tightening torque of the main bearing cap bolts: 25 Nm + 90°.
Tighten the bolts gradually in four or five steps, then tighten to the specified torque. Tighten the bolts 90 degrees.
Check the freedom of rotation of the crankshaft and measure the axial clearance.
Pic. 2.120. Installation of a back epiploon of a cranked shaft
With a special tool (mandrel for installing the rear oil seal of the crankshaft 09231-2100) Establish a back epiploon of a cranked shaft in the epiploon case, as it is shown in drawing 2.120. Be careful to correctly position the mandrel so as not to damage or deform the oil seal during installation.
Pic. 2.121. Scheme of the correct installation of the stuffing box
Install the seal so that the hole (arrow in Figure 2.121) oil separator pointing downwards (to the oil pan).
Install the seal housing on the new gasket. Tighten the mounting bolts.
The moment of an inhaling of bolts of fastening of the case of an epiploon: 10–12 Н·м.
Models with manual transmission: install the rear plate of the cylinder block and tighten the bolts of its fastening, install the flywheel. Tighten the mounting bolts to the specified torque.
Flywheel tightening torque: 130–140 Nm.
Models with automatic transmission: install the sleeve and adapter on the crankshaft, install the automatic transmission drive plate. Tighten the mounting bolts to the specified torque.
Tightening torque of the automatic transmission plate mounting bolts: 130–140 Nm.