Usage:
START BY:
a. remove timing gear cover
b. remove flywheel housing
c. remove pistons and connecting rods
1. Turn the crankshaft until the "C" mark on the crankshaft drive gear is in alignment with the "C" mark on the camshaft drive gear as shown.
NOTE: The main bearing caps are installed with the part number toward the front of the engine. Each cap has a number on the front of the cap which is the same as the number on the camshaft side of the cylinder block.
2. Remove the three center main bearing caps (1).
3. Remove thrust bearings (2) from each side of the center crankshaft journal.
4. Remove bolt (3). Remove the oil pickup tube support strip and the clip from the cylinder block as a unit.
5. Install one of the flywheel bolts in the end of the crankshaft.
6. Fasten a nylon strap and a hoist on crankshaft (4) as shown.
7. Remove the two end caps.
| NOTICE |
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Be careful not to damage the crankshaft journals when the crankshaft is removed. |
8. Remove crankshaft (4) from the cylinder block. The weight of the crankshaft is 52 kg (115 lb.).
| NOTICE |
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If new main bearings are not to be installed during crankshaft installation, put identification marks on the original bearings as to their location in the engine. |
9. Remove the crankshaft main bearings from the cylinder block and from the main bearing cap.
10. Check the condition of the main bearings and crankshaft. Make reference to Guideline For Reusable Parts: Main And Connecting Rod Bearings, Form No. SEBF8009 and Visual Inspection Of Crankshafts, Form No. SEBF8043.
11. Use tooling (A), and remove the drive gear from the crankshaft.
Install Crankshaft And Gear
1. Heat the crankshaft drive gear to a maximum temperature of 315° (600°F). Install drive gear (1) on the crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.
2. Clean the surfaces in the cylinder block for the main bearings. Install the upper main bearing halves (bearings with the oil hole) in the cylinder block.
NOTE: Install the main bearings dry when the clearance checks are made. Put clean oil on the main bearings for final assembly.
3. Fasten a nylon strap and a hoist on crankshaft (2), and put it in position in the cylinder block with the "C" marks on the camshaft drive gear and crankshaft drive gear in alignment.
4. Install a thrust plate (4) on each side of the No. 3 main bearing saddle. Put the side of the thrust plate which has the identification mark "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.
5. Put the clip and oil pickup tube support strip in position on the cylinder block as a unit, and install bolt (3) that holds them in place.
6. Clean the surfaces of the main bearing caps for the main bearings. Install the lower main bearing halves in the main bearing caps.
NOTE: Be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.
NOTE: For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.
7. Check the main bearing clearance with Plastigage (A). Install the Plastigage between the crankshaft and the main bearing.
NOTE: When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage (A). The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance.
| NOTICE |
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When the bearing caps are installed, make sure the caps are installed with the part number toward the front of the engine and the location number is the same as the number on the outside (camshaft side) of the engine block. Also, when using Plastigage to check bearing clearances, do not use an impact wrench to tighten the bearing cap bolts the additional 60° ± 5°. |
8. Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads. Install the main bearing caps and bolts. Tighten the bolts on the side where the main bearing tabs are located, to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark. Remove main bearing caps (5), and measure the width of Plastigage (A) while it is in the bearing cap. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). Maximum permissible clearance with used main bearings is 0.18 mm (.007 in.).
9. Put 2P2506 Thread Lubricant on the bolt threads and the contact surface of the bolt heads. Put the main bearing caps in the same position on the cylinder block as they were when they were removed. Install the bolts, and tighten the bolts on the side where the main bearing tabs are located to a torque of 61 ± 6 N·m (45 ± 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 ± 5 N·m (45 ± 4 lb.ft.). Put a mark on each bolt head and the bearing caps. Turn the bolts, that are opposite the main bearing tabs and extra 60° ± 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° ± 5° from the mark.
10. Check the end play of the crankshaft with tool (B). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 (center) main bearing. The end play with new bearings must be 0.064 to 0.480 mm (.0025 to .0189 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.). Make a replacement of the thrust bearings if needed.
END BY:
a. install pistons and connecting rods
b. install flywheel housing
c. install timing gear cover