55. Crankshaft and Bearings Clean and Inspect
Crankshaft and Bearings Cleaning and Inspection- J 39477 Gear Puller
- J 36660-A Torque/Angle Meter
1. Use the J 39477 gear puller to remove the crankshaft gear.
2. Clean the crankshaft and bearings.
3. Inspect the crankshaft for the following conditions.
- Excessive wear or damage on the surface of the crankshaft journals.
- Excessive wear or damage on the surface of the crankpin.
- Excessive wear or damage on the oil seal fitting surface.
- Inspect the oil ports for obstructions.
- Inspect the crankshaft pins for excess wear or damage. Replace pins if any damage is found.
4. Measure the crankshaft run out.
- Mount the crankshaft in wooden V-blocks.
- Set a dial indicator to the center of the crankshaft journal.
- Turn the crankshaft in the normal direction of rotation.
- Record readings. The production value is 0.05 mm (0.0020 inch) and the service limit is 0.44 mm (0.0173 inch).
5. Measure the crankshaft journal diameter across four points.
- The crankshaft journal outside diameter is 79.905 - 79.925 mm (3.1459 - 3.1466 inch) and the service limit is 79.89 mm (3.1453 inch).
- Replace the crankshaft if the measured value is less than the service limit.
6. Measure the crankpin outside diameter across four points.
- The crankpin outside diameter is 62.902 - 62.922 mm (2.4765 - 2.4772 inch) and the service limit is 62.88 mm (2.4756 inch).
- Replace the crankshaft if the measured value is less than the service limit.
7. Install the crankshaft gear to the crankshaft.
7.1. Heat the crankshaft gear to 190 - 250°C (374 - 482°F). Do not heat the gear over 270°C (518°F).
7.2. Align the groove on the gear with the crankshaft pin.
7.3. Install the crankshaft gear to the crankshaft using a suitable tool.
Crankshaft Bearing Selection
There are two methods for selecting the proper size crankshaft bearings. The first one is to select the bearing grade (color code) based on the cylinder block grade and the crankshaft journal grade from the Crankshaft Bearing Grade chart. The second is the plastic gauge method.
Crankshaft Bearing Selection Grade Chart Method
1. The cylinder block grade is indicated on the right lower portion of the cylinder block.
2. The crankshaft journal grade is indicated on the number 1 crankshaft counterweight.
3. Match the cylinder block grade and the crankshaft journal grade.
4. From the Crankshaft Bearing Grade chart, determine which bearing grade (color code) is required.
5. Verify the crankshaft bearing clearance using the plastic gauge method.
Crankshaft Bearing Selection Plastic Gauge Method
1. Clean the cylinder block bearing fitting surfaces.
2. Clean the crankshaft and upper bearings (1) and lower bearings (2).
3. Install the bearings into the cylinder block and the bearing caps.
4. Install the crankshaft into the cylinder block.
5. Rotate the crankshaft approximately 30 degrees to seat the bearings.
6. Place the plastic gauge over the crankshaft journal across the full width of the bearing.
Note: Do not allow the crankshaft to rotate at any time during bearing cap installation and tightening or the plastic gauge measurement will be inaccurate.
7. Install the crankshaft bearing caps.
Notice: This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.
Notice: Refer to Fastener Notice in Service Precautions.
8. Install the original crankshaft bearing cap bolts.
9. Tighten the crankshaft bearing cap bolts in the proper sequence.
- 1st step 98 Nm (72 ft. lbs.).
- 2nd step 132 Nm (97 ft. lbs.).
- 3rd step 30 degrees using J 36660-A.
10. Install the original crankshaft bearing cap side bolts.
- Tighten the crankshaft bearing cap side bolts in the proper sequence to 78 Nm (58 ft. lbs.).
11. Remove the crankshaft bearing cap bolts.
12. Remove the crankshaft bearing caps.
13. Compare the width of the plastic gauge with the scale printed on the plastic gauge container.
14. Select the crankshaft bearing grade that provides the proper oil clearances. The production specification for crankshaft bearing clearance is 0.037 - 0.072 mm (0.0015 - 0.0028 inch) and the service limit is 0.014 mm (0.0055 inch).
15. After the bearing grades have been selected, discard the crankshaft bearing cap bolts and the crankshaft bearing cap side bolts. Use NEW bolts for final assembly.