Usage:
Start By:
a. remove oil pump
b. remove timing gear cover
c. remove flywheel housing
| NOTICE |
|---|
To prevent damage to the intake and exhaust valves, an adjustment must be made to the valve clearance setting. Loosen the nuts on each rocker arm and move the adjustment screw on each rocker arm away from the bridge as far as possible. |
1. Put engine in position on tooling (A), and turn the engine over on its side. Make sure the blocks that are used as support for the top of the engine are against the cylinder head only and not against the exhaust manifold or valve cover bases.
2. Loosen the nuts that hold each connecting rod bearing caps (1) in position. Turn the crankshaft if necessary to loosen all the nuts. Make sure the nuts are still tight enough to hold the bearing caps in place when the crankshaft is turned.
3. Turn the crankshaft so that "V" crankshaft gear aligns with "V" mark (3) on the idler gear.
4. Remove the bearing caps that hold the connecting rods in position against the crankshaft.
5. Remove bearings (4) from each bearing cap. Make sure that each bearing is kept with the bearing cap from which the bearing is removed from for correct installation purposes.
6. Remove crankshaft main bearing caps No. 2 through No. 6.
7. Push the pistons as far away as possible from the crankshaft.
8. Remove bearing (6) from each crankshaft main bearing cap. Make sure that each bearing is kept with the crankshaft main bearing cap from which the bearing is removed from for correct installation purposes.
9. Remove two thrust plates (7) from the center main bearings.
10. Fasten tooling (B) and a hoist to the crankshaft as shown.
11. Remove the No. 1 and No. 7 crankshaft main bearing caps.
12. Use tooling (B) and a hoist to remove crankshaft (8) from the cylinder block. The weight of the crankshaft for a 3412 Engine is approximately 181 kg (400 lb).
13. Use tooling (C) to remove gear (9) from the crankshaft. Use tooling (D) to remove the dowel that is under the gear if a replacement is necessary.
14. Use tooling (E) to remove pin (10) from the crankshaft if a replacement is necessary.
15. Put identification on bearings (11) and (12) as to their location on the cylinder block or connecting rod. Remove bearings (11) and (12).
Install Crankshaft
NOTE: Do not put oil on the bearings until the bearing clearance has been checked.
1. Install bearings (1) in the connecting rods they were removed from. Make sure the tab in each bearing is in alignment with the notch in each connecting rod.
2. Install bearings (2) in the cylinder block. Make sure the tab in each bearing aligns with the notch in the cylinder block.
3. Install pin (3) in the end of the crankshaft. Install the pin so that the pin extends a maximum of 6.40 mm (.252 in) above the surface.
4. Install the dowel in the crankshaft that puts gear (4) in the correct position. Install the dowel so that it extends 4.10 ± 0.50 mm (.161 ± .020 in) above the surface.
5. Heat gear (4) to a maximum temperature of 233°C (451°F).
NOTE: Gear (4) must be installed on the crankshaft with the "V" timing mark toward the outside.
6. Install gear (4) on the crankshaft. Make sure the notch in the gear aligns with the dowel on the crankshaft.
7. Fasten tooling (A) and a hoist to the crankshaft (5), as shown. Install the crankshaft in the engine. The weight of a crankshaft for a 3412 Engine is approximately 181 kg (400 lb).
8. Make sure that "V" mark (6) on the crankshaft is in alignment with "V" mark (7) on the idler gear.
9. Install the bearings in the No. 1 and No. 7 crankshaft main bearing caps. Install the No. 1 and No. 7 crankshaft main bearing caps to hold the crankshaft in place.
NOTE: The side of each thrust plate (8) with the words "BLOCK SIDE" must be installed with this side toward the cylinder block.
10. Put clean oil on thrust plates (8). Install thrust plates (8) next to the center main bearings.
NOTE: Do not put oil on bearings (9) until the bearing clearances have been checked.
11. Put bearings (9) in position in crankshaft main bearing caps (10).
12. Check the crankshaft main bearing clearance with Plastigage (C) as follows:
a. Put a piece of Plastigage (C) between the crankshaft bearing journal surface and bearing (9).
b. Install the crankshaft main bearing caps (10) with the arrow on each cap toward the front of cylinder block. Each crankshaft main bearing cap has a number on the bottom surface and must be installed in the same position as the correct number on the left side of the cylinder block.
c. Put clean oil on the threads of the cap bolts. Install the cap bolts finger tight.
d. Tighten the bolts on the tab end of the caps first to a torque of 258 ± 14 N·m (190 ± 10 lb ft).
e. Tighten the bolts on the other end of the caps to a torque of 258 ± 14 N·m (190 ± 10 lb ft).
| NOTICE |
|---|
Do not use an impact wrench to tighten the bolts the additional 120 degrees. |
f. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end of the cap 120 degrees (1/3 turn) more. Tighten the bolts on the tab end of the cap 120 degrees (1/3 turn) more.
13. Remove the crankshaft main bearing caps and measure the Plastigage. The clearance for new bearings must be 0.91 to 0.186 mm (.0036 to .0073 in). The maximum clearance for used bearings is 0.25 mm (.010 in).
14. Put clean engine oil on the bearings in the crankshaft main bearing caps. Use Steps 12b through 12f to install the crankshaft main bearing caps on the engine.
NOTE: Do not put oil on bearing (11) until the bearing clearance has been checked.
15. Install bearing (11) in connecting rod bearing cap (12). Make sure the tab on each bearing aligns with the notch in each connecting rod bearing cap.
16. Install connecting rod caps (12) on the connecting rods. Make sure the Plastigage is in position between the crankshaft surface and bearing (11).
NOTE: When the connecting rod caps are installed, Make sure the number on the side of each cap is next to and the same as the number on the side of the connecting rod.
17. Put clean engine oil on the threads of bolts (13). Install the nuts that hold the connecting rod caps in position. Tighten each nut to a torque of 81 ± 8 N·m (60 ± 6 lb ft).
| NOTICE |
|---|
Do not use an impact wrench to tighten the nuts 120 degrees (1/3 turn) more. |
18. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees (1/3 turn) more.
19. Remove the cap, and measure the Plastigage. The connecting rod bearing clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (.010 in).
20. Put clean oil on each bearing in the connecting rod bearing caps. Install the connecting rod bearing caps. Repeat Steps 17 and 18.
| NOTICE |
|---|
Because of the position of some of the nuts on the connecting rod caps, not all of the bearing clearances can be checked at the same time. It will be necessary to turn the crankshaft to check the rest of the bearing clearances. Do not turn the crankshaft unless all the connecting rod caps are in position on the engine. Install all the connecting rod caps and tighten the nuts enough so that the crankshaft will not be damaged when it is turned. |
21. Check the end play of the crankshaft with tooling (B). Make sure the dial indicator is against a machined surface. End play with new thrust plates must be 0.15 to 0.51 mm (.006 to .020 in). The maximum end play with used thrust plates is 0.89 mm (.035 in).
22. Make an adjustment to the valve clearance setting. See "Valve Clearance Setting" in the Testing And Adjusting.
End By:
a. install flywheel housing
b. install timing gear cover
c. install oil pump