Removal and Replacement

REMOVAL
1. Remove the engine assembly.
2. Separate transaxle from engine.
3. Mount engine on an engine stand.
4. Remove the oil filter.
5. Remove the oil pan and oil pick-up tube.
6. Remove the timing chain cover.
7. Remove timing chain and sprockets.
8. Remove crankshaft rear oil seal and retainer.
9. Rotate the crankshaft until connecting rod cap is accessible.
10. Mark connecting rod cap position using a suitable marker/scribe tool.
11. Remove connecting rod bearing cap. Use care to prevent damage to the crankshaft bearing surfaces.
12. Repeat removal procedure for each connecting rod cap.
13. Remove and discard the main bearing cross bolts and washers (3.8L engine only).

NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly.

14. Remove the main bearing cap bolts
15. Remove the main bearing caps.
16. Remove the crankshaft from engine block.

INSPECTION

Fig.54:

The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 54). Limits of taper or out of round on any crankshaft journals should within specifications. Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.

CAUTION: With the nodular cast iron crankshafts, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine.

INSTALLATION
1. Lubricate with engine oil and install the crankshaft main bearing halves in the engine block.

Fig.56:

2. Position the crankshaft in engine block (Fig. 56).
3. Perform main bearing fitting procedure.

Fig.55:

4. Inspect main cap bolts for stretching (Fig. 55). Replace bolts that are stretched.

NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 55).

5. Install the main bearing caps and bolts. Tighten bolts to 41 Nm (30 ft. lbs.) plus 1/4 turn.

NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly.

Fig.57:

6. Install and tighten the NEW cross bolts and washer assemblies (3.8L engine only) to 61 Nm (45 ft. lbs.) (Fig. 57).
7. Position and install the connecting rod and bearing caps on the crankshaft.
8. Install the crankshaft rear oil seal.
9. Install the crankshaft sprocket.
10. Install the timing chain and camshaft sprocket.
11. Install the timing chain cover.
12. Install the oil pick-up tube and oil pan.
13. Install the transaxle to the engine.
14. Install the engine assembly.