Crankshaft Repair Procedures

Disassembly

1. 1
   Remove the engine and transaxle assembly from the vehicle. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2. 2
   Remove the dual clutch transmission (DCT). (Refer to Dual Clutch Transmission (DCT) System - "Dual Clutch Transmission (DCT)")
3. 3
   Remove the external damper flywheel. (Refer to Cylinder Block - "Flywheel with External Damper")
4. 4
   Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")
5. 5
   Install the engine on an engine stand for disassembly.
6. 6
   Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
7. 7
   Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
8. 8
   Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
9. 9
   Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")
10. 10
    Remove the oil pan and oil screen. (Refer to Lubrication System - "Oil Pan")
11. 11
    Remove the oil cooler. (Refer to Lubrication System - "Engine Oil")
12. 12
    Remove the oil pan frame. (Refer to Cylinder Block - "Piston and Connecting Rod")
13. 13
    Remove the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
14. 14
    Check the oil clearance of the crankshaft main bearings.
15. 15
    Remove the main bearing caps (A).

    

16. 16
    Check the crankshaft end play.
17. 17
    Lift the crankshaft (A) out of the cylinder block, taking care not to damage the journals.

    

Inspection

1. 1
   Check the oil clearance of the crankshaft main bearings.

   1. To check the main bearing oil clearance, remove the main bearing caps with their lower bearings.
   2. Clean each main journal and lower bearing with a clean shop towel.
   3. Place one strip of Plastigage on each main journal.
   4. Install the bearing caps with their lower bearings, then tighten the bolts. Tightening torque: [17.7–22 N·m] + [88° – 92°]
   5. Remove the bearing caps with lower bearings again and measure the widest part of the Plastigage. Bearing oil clearance: No. 1, 2, 3, 4, 5: 0.020–0.041 mm (0.0007–0.0016 in.)

      

   6. If the Plastigage is too wide or too narrow, remove the upper and lower bearings, then install new bearings with the same color code. Re-check the oil clearance.
   7. If the Plastigage indicates that the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance. Location of the cylinder block main journal bore marks: Letters are stamped on the side of the block as the size mark for each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crankshaft (main journal size marks), to correctly select the bearings.

      

      Cylinder Block Main Journal Bore Grade

      Mark	Cylinder Block Main Journal Bore Inside Diameter
      A	52.000–52.006 mm (2.0472–2.0475 in.)
      B	52.006–52.012 mm (2.0475–2.0477 in.)
      C	52.012–52.018 mm (2.0477–2.0479 in.)

      
      Location of the mark on the crankshaft main journal

      

      Crankshaft main journal identification

      Mark	Outer diameter of the crankshaft main journal
      A	47.954–47.960 mm (1.8879–1.8882 in.)
      B	47.948–47.954 mm (1.8877–1.8879 in.)
      C	47.942–47.948 mm (1.8875–1.8877 in.)

      
      Crankshaft Main Bearing Color Location

      

      Crankshaft main bearing identification

      Mark	Color	Thickness of the crankshaft main bearing
      		№1, 2, 3, 4, 5
      A	Blue	2.026–2.029 mm (0.0798–0.0799 in.)
      B	Black	2.023–2.026 mm (0.0796–0.0798 in.)
      C	None	2.020–2.023 mm (0.0795–0.0796 in.)
      D	Green	2.017–2.020 mm (0.0794–0.0795 in.)
      E	Red-Yellow	2.014–2.017 mm (0.0793–0.0794 in.)

   8. Select the bearing using the selection table. Crankshaft Main Bearing Selection Table

      Bearing Classification Assembly		Crankshaft Main Journal Bore Mark on Cylinder Block
      		A	B	C
      Crankshaft main journal mark	1	E (Red-Yellow)	D (Green)	C (None)
      	2	D (Green)	C (None)	B (Black)
      	3	C (None)	B (Black)	A (Blue)

2. 2
   Check the crankshaft end play. Using a dial indicator, measure the end play by prying the crankshaft forward and backward with a screwdriver. Crankshaft End Play Standard: 0.05–0.25 mm (0.0020–0.0098 in.) Limit: 0.30 mm (0.0118 in.)

Installation

1. 1
   Install the crankshaft main bearings.

   1. Align the bearing tab with the tab groove of the cylinder block, then insert the five upper bearings (A).

      

   2. Align the bearing tab with the tab groove of the main bearing cap (B), then insert the five lower bearings (A).

      

   3. Apply a coat of engine oil after installing the main bearings.
2. 2
   Install the thrust bearings. Install the thrust bearing (A) on the No. 3 cylinder block journal so that the oil grooves face outward.

   

3. 3
   Install the crankshaft to the cylinder block.
4. 4
   Install the main bearing caps and tighten the main bearing cap bolts.

   1. Apply a thin coat of engine oil to the threads and under the head of the bearing cap bolts.
   2. Install and tighten the 10 bearing cap bolts evenly in several passes, in the sequence shown. Tightening torque: [17.7 - 22 N·m] N·m + [88 - 92°]. Using SST (09221-4A000), tighten the main bearing cap bolts (A).

      

   3. Make sure the crankshaft rotates smoothly.
5. 5
   Check the crankshaft end play.
6. 6
   Install the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
7. 7
   Install the ladder frame. (See Cylinder Block - Ladder Frame)
8. 8
   Install the remaining parts in the reverse order of removal.