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Crankshaft And Crankshaft Bearing

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  1. Clean the crankshaft completely, and check it for cracks using liquid penetrant tester.
  2. Using a dial gauge, check the crankshaft bend. If it exceeds the limit, grind to correct the crankshaft journal or replace the crankshaft.
    NOTE:
    • Measurement should be performed at a temperature of 20°C (68°F).
    • If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.
    • When grinding to correct the crankshaft journal, refer to step 3).

    Crankshaft bend: 

    Limit 

    0.035 mm (0.0014 in)

    G09480636Courtesy of SUBARU OF AMERICA, INC.
  3. Using a micrometer, check the outer diameter of crankshaft pin, outer diameter of journal, cylindricality, and out-of-roundness. If it is not within the standard, replace the connecting rod bearing or crankshaft bearing, and grind to correct the crankshaft pin or journal or replace the crankshaft as required.
    NOTE:
    • Measurement should be performed at a temperature of 20°C (68°F).
    • Select the suitable size connecting rod bearing or crankshaft bearing when replacing the connecting rod bearing or crankshaft bearing.
    • When grinding to correct the crankshaft pin or journal, finish them to the suitable outer diameter as shown in the table below according to the undersize bearing to be used.
    Unit: mm (in)
    Bearing Connecting rod bearing thickness (at center) Crankshaft pin outer diameter Crankshaft bearing thickness (at center) Crankshaft journal outer diameter
    #1, #2, #3, #4 #5
    Standard Standard Standard Standard Standard
    Standard size 1.492 - 1.508 (0.0587 - 0.0594) 49.976 - 50.000 (1.9676 - 1.9685) 2.498 - 2.513 (0.0983 - 0.0989) 2.496 - 2.511 (0.0983 - 0.0989) 67.985 - 68.003 (2.6766 - 2.6773)
    0.03 (0.0012) Undersize 1.511 - 1.515 (0.0595 - 0.0596) 49.946 - 49.970 (1.9664 - 1.9673) 2.519 - 2.522 (0.0992 - 0.0993) 2.517 - 2.520 (0.0991 - 0.0992) 67.955 - 67.979 (2.6754 - 2.6763)
    0.05 (0.0020) Undersize 1.521 - 1.525 (0.0599 - 0.0600) 49.926 - 49.950 (1.9656 - 1.9665) 2.529 - 2.532 (0.0996 - 0.0997) 2.527 - 2.530 (0.0995 - 0.0996) 67.935 - 67.959 (2.6746 - 2.6755)
    0.25 (0.0098) Undersize 1.621 - 1.625 (0.0638 - 0.0640) 49.726 - 49.750 (1.9577 - 1.9587) 2.629 - 2.632 (0.1035 - 0.1036) 2.627 - 2.630 (0.1034 - 0.1035) 67.735 - 67.759 (2.6667 - 2.6677)

    Crankshaft pin: 

    Cylindricality 

    Limit 

    0.006 mm (0.0002 in)

    Out-of-roundness 

    Limit 

    0.005 mm (0.0002 in)

    Grinding limit (dia). 

    To 49.726 mm (1.9577 in)

    Crankshaft journal: 

    Cylindricality 

    Limit 

    0.006 mm (0.0002 in)

    Out-of-roundness 

    Limit 

    0.005 mm (0.0002 in)

    Grinding limit (dia). 

    To 67.735 mm (2.6667 in)

    G08317267Courtesy of SUBARU OF AMERICA, INC.
  4. Inspect the crankshaft bearing for scar, peeling, seizure, melting or wear, etc.
  5. Use a thickness gauge to check the thrust clearance of crankshaft at thrust of #5 crankshaft bearing. If it is not within the standard, replace the #5 crankshaft bearing.
    NOTE:
    • Measurement should be performed at a temperature of 20°C (68°F).
    • Set all the crankshaft bearings onto the cylinder block, then mount the crankshaft on the cylinder block, and use a thickness gauge to measure the thrust clearance of crankshaft.
    • Select the #5 crankshaft bearing of suitable size by referring to step  3 when replacing #5 crankshaft bearing.

    Crankshaft thrust clearance: 

    Standard 

    0.130 - 0.308 mm (0.0051 - 0.0121 in)

    G09480638Courtesy of SUBARU OF AMERICA, INC.
  6. Check the oil clearance on each crankshaft bearing using plastigauge.
    NOTE: Measurement should be performed at a temperature of 20°C (68°F).
    1. Install the cylinder block LH to the engine stand.
      CAUTION:
      • When the engine stand is not used, place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
      • Be careful not to scratch the mating surface of cylinder block during work.
    2. Remove the liquid gasket from cylinder block.
    3. Clean each crankshaft bearing and crankshaft journal.
    4. Set each crankshaft bearing to the cylinder block.
      CAUTION: When performing the operation of the cylinder block RH, be careful of the following.
      1. Place a wood board wrapped with a waste cloth to prevent the knock pin damage and to stabilize the cylinder block before work.
      2. Be careful not to scratch the mating surface of cylinder block during work.
      G09480561Courtesy of SUBARU OF AMERICA, INC.
    5. Set the crankshaft to the cylinder block LH.
      G09480563Courtesy of SUBARU OF AMERICA, INC.
    6. Place a plastigauge across the crankshaft journals and set the cylinder block RH to the cylinder block LH.
    7. Apply a coat of engine oil to the washers and cylinder block mounting bolt threads.
      NOTE: To prevent mixture of engine oil into the water jacket, do not apply a large amount.
    8. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 1: Cylinder Block LH Bolts With (Tightening Sequence)
      G09480565Courtesy of SUBARU OF AMERICA, INC.
    9. Loosen all mounting bolts by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 2: Cylinder Block LH Bolts With (Loosening Sequence)
      G09480558Courtesy of SUBARU OF AMERICA, INC.
    10. Tighten all mounting bolts with a torque of 35 N.m (3.6 kgf-m, 25.8 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 3: Cylinder Block LH Bolts With (Tightening Sequence)
      G09480565Courtesy of SUBARU OF AMERICA, INC.
    11. Loosen the mounting bolts (4 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 4: Cylinder Block LH Bolts With (Tightening Sequence) (4 Places)
      G09480568Courtesy of SUBARU OF AMERICA, INC.
    12. Tighten the mounting bolts (4 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 5: Cylinder Block LH Bolts With (Tightening Sequence) (4 Places)
      G09480569Courtesy of SUBARU OF AMERICA, INC.
    13. Using angle gauge, tighten the mounting bolts (4 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle: 

      60°±2°

      Fig 6: Cylinder Block LH Bolts With (Tightening Sequence) (4 Places)
      G09480570Courtesy of SUBARU OF AMERICA, INC.
    14. Loosen the mounting bolts (6 places) by 180° in numerical order as shown in the figure.
      CAUTION: When loosening the mounting bolts, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 7: Cylinder Block LH Bolts With (Loosening Sequence) (6 Places)
      G09480571Courtesy of SUBARU OF AMERICA, INC.
    15. Tighten the mounting bolts (6 places) with a torque of 17 N.m (1.7 kgf-m, 12.5 ft-lb) in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified torque, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.
      Fig 8: Cylinder Block LH Bolts With (Loosening Sequence) (6 Places)
      G09480572Courtesy of SUBARU OF AMERICA, INC.
    16. Using angle gauge, tighten the mounting bolts (6 places) with specified angle in numerical order as shown in the figure.
      CAUTION: When tightening the mounting bolts with specified angle, hold the cylinder block LH while not holding the cylinder block RH to ensure the joint accuracy of the cylinder block.

      Tightening angle: 

      60°±2°

      Fig 9: Cylinder Block LH Bolts With (Tightening Sequence) (6 Places)
      G09480573Courtesy of SUBARU OF AMERICA, INC.
    17. Loosen the cylinder block mounting bolts in numerical order as shown in the figure, and separate the cylinder block RH and LH.
      NOTE: Lift the cylinder block RH slightly, and confirm that the crankshaft is remaining in the cylinder block LH. If the cylinder block RH is lifted carelessly when separating, the crankshaft may stick to cylinder block RH, then fall off.
      Fig 10: Cylinder Block LH Bolts With (Loosening Sequence)
      G09480558Courtesy of SUBARU OF AMERICA, INC.
    18. Determine the crankshaft oil clearance by matching the widest point of the plastigauge on each journal against scale printed on a package of the plastigauge. If it is not within the standard, replace the crankshaft bearing, and grind to correct the crankshaft journal or replace the crankshaft as required.
      NOTE:
      • Select the crankshaft bearing of suitable size by referring to step 3) when replacing crankshaft bearing.
      • When grinding to correct the crankshaft journal, finish it to the suitable outer diameter by referring to step  3 according to the undersize bearing to be used.

      Crankshaft oil clearance: 

      Standard 

      0.013 - 0.031 mm (0.0005 - 0.0012 in)

      G08317260Courtesy of SUBARU OF AMERICA, INC.
    19. Completely remove the plastigauge.
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