Crankshaft

GENERAL INFORMATION

Checking connecting rod side clearance A. MEASURING CONNECTING ROD SIDE CLEARANCE

Remove or disconnect:

PROCEDURE.

1. Engine..

2. Drain oil..

3. Install engine on stand..

4. Remove spark plugs

20..

5. Pulley 145 with hub..

6. Timing belt cover..

7. Timing belt 44, loosening the water pump mounting bolts.

8. Flywheel

116..

9. Oil pan

125..

10. Crankshaft gear 141..

11. Rear timing belt cover..

12. Oil pump

137..

13. Connecting rod caps 157 with bearing shells, marking beforehand..

14. Move pistons 160 with connecting rods 159 away from the crankshaft journals..

15. Main bearing caps 122 with bearing shells 120 and

121. Preliminarily

mark the parts..

16. Crankshaft..

Clean.

PROCEDURE.

1. Oil, dirt and carbon deposits..

2. Oil passages from plugs and deposits.

Inspection

PROCEDURE.

1. Keyway.

2. Threads.

3. Bearing journals and thrust flanges for presence of

– cracks.

– metal flaking.

– pitting.

– roughness.

– grooves.

– signs of overheating.

Warning.

Inspect the corresponding bearing shells for embedded foreign particles.

If such defects are found, determine the origin of these

foreign particles..

If there are cracks or other deep defects on the working surfaces,

the crankshaft must be replaced. Small irregularities can be smoothed with fine

emery cloth moistened with engine oil. Scores are removed with a fine

grinding stone..

Measure

PROCEDURE.

Crankshaft journals. Measure taper and out-of-round (ovality) using a dial gauge or micrometer.

If the dimensions and shape of the journals are within the specified limits, record the measurement results for subsequent selection of the bearing shell set. If the condition of the journals is

unsatisfactory, the shaft can be restored by regrinding the journals.

Shafts with rolled fillets must be replaced..

Warning.

Check the position of the main bearing lugs. If they are located

not in line, the crankshaft is bent and must be replaced..

Installation

PROCEDURE.

1. New bearing shells 120, 121, crankshaft

119..

2. Main bearing caps 122 with new bearing shells. Do not tighten bolts 123. Lubricate the bearing shells with oil beforehand..

3. Install connecting rod big ends with new bearing shells 158 onto the crankshaft journals.

4. Connecting rod caps with new bearing shells. Do not tighten connecting rod bolts

156..

Lubricate the bearing shells with oil beforehand..

5. Center the thrust bearings by lightly tapping the ends of the crankshaft with a hammer with a rubber head

121..

6. Tighten the main bearing bolts to 50 N·m torque, then tighten additionally.

tighten them by turning through an angle of 45°–60°. Check the crankshaft end play. It

should be within 0.07–0.30 mm..

7. Tighten the connecting rod bearing cap bolts to 25 N·m, then tighten additionally.

tighten them by turning through an angle of 30°..

8. Measure the side clearance of all connecting rods. The clearance should be within 0.07–0.

242 mm..

9. Oil pump

137..

10. Install a new front crankshaft seal using special tool KM-

417..

11. Rear timing belt cover..

12. Crankshaft gear

141..

13. Oil pan

125..

14. New rear seal

117..

15. Flywheel. Tighten the bolts to 35 N·m, then tighten additionally.

by turning through an angle of 30°–45°..

16. Timing belt and cover..

17. Pulley. Tighten the bolts to 55 N·m..

18. Spark plugs..

19. Install the engine in the vehicle..

20. Fill the engine oil.