Checking and repairing the crankshaft [Toyota Corona T190]

1. Checking the crankshaft runout.

• a) Place the crankshaft on the prisms.
• b) Using a dial indicator, check the runout of the crankshaft on the central main journal.
• Maximum runout:
  • a series engines - 0.03 mm
  • c series engines - 0.05 mm

If the runout is greater than the maximum allowable, replace the crankshaft.

2. Check the connecting rod and main journals.

• a) Using a micrometer, measure the diameter of each connecting rod and main journal in two mutually perpendicular planes, as shown in the figure.

• Engines 4A-FE, 7A-FE:
  • main journal diameter:
    • nominal - 47.982-48.000 mm
    • repair - 47.745-47.755 mm
  • connecting rod journal diameter:
    • 4A-FE:
      • nominal - 39.985-40.000 mm
      • repair - 39.745-39.755 mm
    • 7A-FE:
      • nominal - 47.988-48.000 mm
      • repair - 47.745-47.755 mm
• Engines 2S, 2S-T:
  • main journal diameter:
    • nominal - 56.982-57.000 mm
    • repair - 56.745-56.755 mm
  • connecting rod journal diameter:
    • nominal - 50.488-50.500 mm
    • repair - 50.245-50.255 mm
• Engines 3S-FE, 3S-GE:
  • main journal diameter:
    • nominal - 54.988-55.003 mm
    • repair - 54.745-54.755 mm
  • connecting rod journal diameter:
    • nominal - 51.985-52.000 mm
    • repair - 51.745-51.755 mm
• 4S-FE Engine:
  • main journal diameter:
    • nominal - 54.988-55.003 mm
    • repair - 54.745-54.755 mm
  • connecting rod journal diameter:
    • nominal - 47.985-48.000 mm
• Engine 5E-FE:
  • main journal diameter:
    • nominal - 49.985-50.000 mm
    • repair - 49.745-49.755 mm
  • connecting rod journal diameter:
    • nominal - 42.985-43.000 mm
    • repair - 42.745-42.755 mm

If the diameter values are outside the specified limits, check the oil clearances. If necessary, regrind or replace the crankshaft.

Note: the repair diameter of the journals is reduced by 0.25 mm compared to the nominal one.

• 6) Check the connecting rod and main journals for taper and out-of-roundness as shown in the previous figure.
• Maximum taper and ovality:
  • 5E-FE — 0.08 mm
  • the rest - 0.02 mm

If the taper or out-of-roundness is greater than the allowable limit, replace the crankshaft.

If necessary, regrind the connecting rod and main journals to the repair size and select repair size bearings (reduced by 0.25 mm) size.