Crankshaft
Crankshaft
Service Repair No - 12.21.33.01
Remove
1. Remove crankshaft front oil seal.
2. Remove crankshaft rear oil seal.
3. Remove engine sump.
4. Remove engine oil filter.
5. Disconnect multiplug from oil pressure switch.
6. Remove crankshaft gear.
7. Remove and discard 16 bolts securing oil pump to cylinder block.
8. Release oil pump from locating dowels, remove oil pump and discard gasket.
9. Remove bolt securing oil pick up strainer, remove strainer and discard 'O' ring.
10. Remove 9 M8 bolts and 2 M6 bolts securing lower crankcase to cylinder block, release and remove lower crankcase.
11. Measure crankshaft end-float.-
12. Position DTI gauge probe onto end of crankshaft as illustrated, push crankshaft away from DTI, zero DTI gauge, push crankshaft in the opposite direction and note reading on gauge.
13. Remove and discard 16 bolts securing bearing ladder to cylinder block.
NOTE: Short length bolts are fitted to the outer edge of the bearing ladder.
14. Release bearing ladder from dowels and remove from cylinder block.
15. Remove main bearing shells and 2 thrust washer halves from bearing ladder, keep in fitted order.
16. Remove 4 dowel bolts and remove big end bearing caps from No 1 and No 2 connecting rods. Keep bearing caps in order.
NOTE: Number stamped below bearing cap bolt is bearing bore size code. Number stamped on connecting rod is cylinder number and letter is weight code.
17. Release connecting rods from crankshaft.
18. Remove bearing shells from connecting rod and cap.
19. Rotate crankshaft, remove bolts securing remaining connecting rod bearing caps. Remove bearing caps and bearing shells from caps. Keep bearing caps in their fitted order.
20. Remove crankshaft, remove main bearing shells and thrust washers from cylinder block.
21. Main bearings-selection: record main bearing code letters from front face of cylinder block. Reading from left to right, the first letter relates to No.1, (front) main bearing journal.
22. Record main bearing code numbers, located on the crankshaft rear web. The first number, reading left to right, relates to number one main bearing journal.
23. Check crankshaft main journal diameters.
24. Diameters should be within tolerances. Replace crankshaft if outside tolerance.
25. Determine appropriate main bearing shells to be fitted from size selection and type tables in general data.
26. Determine main bearing thickness by color code on edge of bearing.
27. Crankshaft big-end journal diameters. Check crankshaft big-end journal diameters and out of round. Renew crankshaft if outside tolerance.
28. Diameters should be within tolerances.
29. Determine big-end bearing thickness by color code on edge of bearing.
30. Connecting rod bearings-selection: record big end journal code letters, located on the rear crankshaft web. The first letter, reading from left to right, relates to the number one big-end journal.
31. Record big-end bearing bore numbers, this will be 7, 8 or 9 located on the connecting rod bearing cap.
32. Big-end bearings selection: Select the required bearing shells from general data.
Refit
1. Clean main bearing shell recesses in cylinder block.
2. Clean crankshaft main bearing and big end bearing journals. Clean bearing shell locations in connecting rods and caps.
3. Fit selected main bearing shells, grooved into cylinder block and plain into bearing ladder.
4. Fit thrust washers to cylinder block.
5. Fit selected big-end bearing shells to connecting rods and caps.
6. Lubricate crankshaft journals with clean engine oil. Hold crankshaft with big end journals horizontal, lower crankshaft into main bearings.
7. Carefully pull connecting rods into place, fit connecting rod caps noting that featherways are on opposite sides and tighten dowel bolts finger tight.
8. Tighten connecting rod bolts to 20 Nm (15 ft. lbs.) and then a further 70°.
9. Using a lint free cloth and a suitable cleaning solvent, clean bearing ladder and mating face on cylinder block.
10. Apply grease to crankshaft thrust washers and fit to bearing ladder with oil grooves facing outwards.
11. Fit bearing ladder and ensure that all bearing shells are seated correctly.
12. Fit new bolts and tighten in the sequence shown on the bearing ladder to 20 Nm (15 ft. lbs.), and then in sequence, tighten a further 90°.
NOTE: The long bolts must be fitted on the inside.
13. Using a lint free cloth and a suitable cleaning solvent, clean mating surfaces on cylinder block and lower crankcase.
14. Apply a continuous bead of sealant, Part No. STC 4600 to paths shown on lower crankcase, then spread to an even film using a roller.
CAUTION: To avoid contamination, assembly should be completed immediately after application of sealant.
15. Position lower crankcase to cylinder block, fit and tighten M8 bolts in the sequence shown to 35 Nm (26 ft. lbs.) and the two rear M6 bolts to 9 Nm (7 ft. lbs.).
16. After one minute, re-torque lower crankcase M8 bolts to 35 Nm (26 ft. lbs.).
17. Clean oil pick-up strainer and mating face.
18. Lubricate new 'O' ring with clean engine oil and fit to pick-up strainer.
19. Position oil pick-up strainer, fit and tighten bolt to 25 Nm (18 ft. lbs.).
20. Using a lint free cloth and a suitable cleaning solvent, clean oil pump, oil seal recess in oil pump body and mating face on cylinder block.
21. Clean oil seal running surface on crankshaft.
22. Fit new oil pump gasket, dry, to cylinder block. Position oil pump to cylinder block, aligning oil pump drive to flats on crankshaft.
23. Fit new Patchlok bolts securing oil pump to cylinder block, tighten bolts in the sequence shown to 25 Nm (18 ft. lbs.).
24. Fit engine sump.
25. Fit crankshaft rear oil seal.
26. Fit crankshaft front oil seal.