Crankshaft - Remove and install

Removal Procedure

Remove the engine oil pump. Remove the front housing. Remove the crankshaft rear seal. Remove the rocker shaft and pushrods. If necessary, remove the cylinder head. If necessary, remove the pistons and connecting rods. The engine should be mounted on a suitable stand and placed in the inverted position. If the cylinder head, the pistons and the connecting rods have not been removed already, remove the connecting rod bearings.

Ensure that the main bearing caps are marked for the location and orientation.

Remove the setscrews (1) and the main bearing caps (2) from the cylinder block.

Remove the lower main bearing shells (3) from the main bearing caps (2). Keep the lower main bearing shells with the respective main bearing caps. The lower main bearing shells are plain bearings that have no oil holes.

Attach lifting straps and a suitable lifting device to the crankshaft (4). Lift the crankshaft (4) out of the cylinder block. The weight of the crankshaft is approximately 61 kg (134.5 lb). Do not damage any of the finished surfaces on the crankshaft. When the crankshaft is removed from the engine, the crankshaft must be supported on a suitable stand in order to prevent damage to the crankshaft timing ring.

Remove the upper main bearing shells (5) from the cylinder block. Keep the upper main bearing shells with the respective main bearing caps. The upper main bearing shells have a groove and two oil holes.

Remove the two thrust washers from number six main bearing in the cylinder block. If necessary, remove the crankshaft timing ring. If necessary, remove the crankshaft gear.

Installation Procedure

Clean the crankshaft and inspect the crankshaft for wear or damage. If necessary, replace the crankshaft or recondition the crankshaft. If necessary, install the crankshaft gear. If necessary, install a new crankshaft timing ring

Ensure that the parent bores for the bearing shells in the cylinder block are clean. Ensure that the threads for the main bearing setscrews in the cylinder block are clean and free from damage.

Clean the main bearing shells and the thrust washers. Inspect the main bearing shells and the thrust washers for wear or damage. If necessary, replace the main bearing shells and the thrust washers. If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.

Install upper main bearing shells (5) to the cylinder block. Ensure that the locating tabs for the upper main bearing shells are seated in the slots in the cylinder block. The upper main bearing shells have a groove and two oil holes.

Lubricate the upper main bearing shells (5) with clean engine oil.

Attach lifting straps and a suitable lifting device to the crankshaft (4). Lift the crankshaft (4) into the cylinder block. The weight of the crankshaft is approximately 61 kg (134.5 lb). Do not damage any of the finished surfaces on the crankshaft. Do not damage the main bearing shells.

Lubricate the thrust washers (6) with clean engine oil. Install the thrust washers (6) into number six main bearing in the cylinder block. The thrust washers have a locating tab at one end. Ensure that the locating tabs are correctly seated in the cylinder block.

Install lower main bearing shells (3) into the main bearing caps (2). Ensure that the locating tabs for the lower main bearing shells are correctly seated into the slots in the bearing caps. The lower main bearing shells are plain bearings that do not have oil holes.

Lubricate the lower main bearing shells (3) and lubricate the journals of the crankshaft (4) with clean engine oil. Install the main bearing caps (2) to the cylinder block. Ensure the correct location and orientation of the main bearing caps (2). The locating tabs for the upper and the lower main bearing shells should be on the same side of the engine.

Lubricate the threads of the setscrews (1) with clean engine oil. Lubricate the underside of the heads of the setscrews (1) with clean engine oil.

Install the setscrews (1) to the main bearing caps (2). Evenly tighten the setscrews in order to pull the caps into position. Ensure that the caps are correctly seated. Do not tap the main bearing caps into position as the bearing shells may be dislodged.

Tighten the setscrews (1) to a torque of 80 N�m (59 lb ft). Turn the setscrews (1) through an additional 90 degrees. Use Tooling to achieve the final torque.

Rotate the crankshaft in order to ensure that there is no binding.

Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Tooling to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling to measure the crankshaft end play. The permissible crankshaft end play is 0.17 mm (0.007 inch) to 0.41 mm (0.016 inch). If the crankshaft has been replaced or the crankshaft has been reconditioned, inspect the height of the piston above the cylinder block. If the crankshaft has not been replaced or the crankshaft has not been reconditioned, install the connecting rod bearings.

If necessary, install the pistons and connecting rods. If necessary, install the cylinder head.

Install the rockershaft and pushrods. Install the crankshaft rear seal. Install the front housing. Install the engine oil pump.