Crankshaft and Main Bearings
Crankshaft and Main Bearings
Service Repair No - 12.21.33.01
Disassembly
1. Remove crankshaft rear oil seal.
2. Remove timing gear cover gasket.
3. Remove bolt securing camshaft gear.
4. Remove timing chain and gears.
5. Remove connecting rod bearings.
6. Reference mark main bearing caps to aid assembly.
7. Remove 10 side bolts securing main bearing caps to block.
8. Collect "Dowty" washers from side bolts. Rear side bolts have Allen heads.
9. Starting at the center main bearing cap, progressively loosen, then remove 2 bolts securing each main bearing cap.
10. Release and remove main bearing caps.
CAUTION: Keep bearing caps, bearings and bolts in their fitted order.
11. Remove crankshaft.
12. Remove main bearings from cylinder block and main bearing caps.
13. Remove key from keyway.
14. Remove rear main sealing washers.
Inspect
1. Clean crankshaft journals and bearing locations in cylinder block.
2. Inspect main bearings for wear and renew if necessary. Main bearings are available in two oversizes. If 2nd oversize bearing is being fitted, it may be necessary to grind thrust face of center main bearing to achieve correct end-float.
^ Main bearing 1st oversize = 0.254 mm (0.01 in).
^ Main bearing 2nd oversize = 0.508 mm (0.02 in).
3. Check main bearing journals for wear and scoring. Measure for ovality; taking 3 measurements at 120° intervals at each end and at center of journals.
^ Journal diameter - standard = 63.487 to 63.500 mm (2.499 to 2.520 in).
^ 1st undersize journal = 63.223 to 63.246 mm (2.511 to 2.512 in).
^ 2nd undersize journal = 62.979 to 62.992 mm (2.509 to 2.510 in).
^ Journal width - standard = 26.975 to 27.026 mm (1.061 to 1.064 in).
^ Maximum ovality = 0.040 mm (0.002 in).
Reassembly
1. Clean main bearing locations in cylinder block and bearing caps.
2. Clean sealant from rear main bearing cap and mating faces.
3. Fit key to keyway.
4. Check threads of main bearing cap bolts for damage, renew bolts in pairs.
5. Lubricate grooved main bearing shells with clean engine oil and fit to their locations in cylinder block.
NOTE: Ensure that the flanged bearing is fitted to the center position.
6. Lubricate crankshaft journals with clean engine oil.
7. Position crankshaft in cylinder block.
8. Attach a DTI to front of cylinder block, move crankshaft rearwards, position stylus of gauge on end of crankshaft and zero gauge.
9. Move crankshaft forwards, measure and record end-float obtained.
^ Crankshaft end-float = 0.08 to 0.26 mm (0.003 to 0.01 in).
10. Lubricate plain bearing shells with clean engine oil and fit to main bearing caps.
11. Fit main bearing caps 1 to 4 only at this stage, ensuring that they are the correct way round and in their fitted order.
12. Lightly lubricate threads of main bearing cap bolts with clean engine oil.
13. Fit main bearing cap bolts but do not tighten at this stage. Do not fit side bolts at this stage.
14. Fit side seals to rear main bearing cap, ensuring that seals protrude approximately 1.5 mm (0.06 in) above bearing cap face.
15. Apply a 3 mm (0.12 in) wide bead of Hylomar PL32 jointing compound to bearing cap rear mating faces on cylinder block.
CAUTION: Ensure sealant does not enter bolt holes.
16. Carefully fit rear main bearing cap assembly, fit but do not tighten bolts.
CAUTION: Ensure engine oil does not enter the side bolt holes in the bearing cap.
17. Lubricate 'Dowty' washers with engine oil and fit to side bolts.
18. Fit but do not tighten side bolts. Rear side bolts are Allen headed.
19. Using the sequence shown, tighten main bearing cap bolts as follows:
^ Initial torque - all main bearing cap bolts and side bolts - 13.5 Nm (10 ft. lbs.).
^ Final torque - main bearing cap side bolts 11 to 15 - 45 Nm (34 ft. lbs.).
^ Final torque - main bearing cap bolts 1 to 8 - 72 Nm (54 ft. lbs.).
^ Final torque - main bearing cap bolts 9 and 10 - 92 Nm (68 ft. lbs.).
^ Final torque - main bearing cap side bolts 16 to 20 - 45 Nm (34 ft. lbs.).
20. Trim off excess material from rear main bearing cap side seals.
21. Fit connecting rod bearings.
22. Clean timing chain and gears.
23. Clean ends of crankshaft and camshaft.
24. Lubricate timing chain assembly with clean engine oil.
25. Align timing marks and fit timing chain assembly.
26. Fit camshaft gear bolt and tighten to 50 Nm (37 ft. lbs.).
27. Fit timing gear cover gasket.
28. Clean crankshaft pulley.
29. Fit crankshaft pulley.
30. Fit crankshaft pulley bolt and tighten to 270 Nm (200 ft. lbs.).
31. Remove tool LRT-12-080 from crankshaft pulley.
32. Clean oil filter and mating face.
33. Lubricate oil filter seal and fit filter to oil pump.
34. Ensure coolant pump and pulley mating faces are clean.
35. Fit coolant pump pulley and tighten bolts to 22 Nm (116 ft. lbs.).
36. Ensure drive belt pulleys are clean and damage free.
37. Fit auxiliary drive belt to pulleys.
38. Fit crankshaft rear oil seal.