Crankshaft: Service and Repair
REMOVE
- Remove the engine/transmission assembly.
- Fit the engine assembly to a suitable stand.
- Remove the oil pan plug and drain the oil into a suitable container.
- Remove the torque converter and drive plate. Withdraw the spacer from the crankshaft.
Timing Chain:
- Move the chain tensioner clear of the locating bracket and slide the tensioner off the dowel pin (2). Disengage the timing chain from the sprockets and remove.
Oil Pan Bolts:
- Invert the engine, remove the oil pan securing bolts (2) and remove the oil pan (1).
Fig. 10 Suction Elbow And Sandwich Plate Removal:
- Remove the suction elbow (2), remove the sandwich plate securing bolts (1) and remove the plate, noting the different stud lengths.
Oil Pickup Pipe:
- Remove the suction pipe securing bolts (1) and disconnect the suction pipe (2) from the elbow.
- Remove the delivery pipe/undershield securing bolts.
- Remove the bolt/washer and nut/washer securing the delivery pipe elbow to the oil pump casing.
NOTE: Leave the bolt at the outboard elbow fastening in position in the oil pump casing. If the bolt is removed for any reason, it must be refitted in a downward direction.
- Draw the delivery pipe/elbow downwards from the bore in the crankcase oil pump casing.
- Remove and discard the gasket.
- Draw the undershield clear.
- Withdraw the crankshaft sprocket and Woodruff key.
Oil Pump Bolts:
- Remove the oil pump securing bolts (1) and remove the pump, drive and Woodruff key.
- Rotate the crankshaft until Numbers 1 and 5 journals are outermost.
- Remove the securing nuts, bearing caps and shells from the connecting rods on one journal noting the cap to connecting rod relationship.
- Remove and discard the shell.
- Displace the connecting rod away from the crankshaft, remove and discard the bearing shell.
- Remove the remaining connecting rods, caps and bearing shells.
- Remove the 3/8" UNF main bearing cap nuts, starting from the center bearing and working outwards. Remove the 1/2" UNF main bearing cap nuts and pillar nuts, starting from the center bearing and working outwards. Note the location of the pillar nuts.
- Lift off the bearing caps, remove and discard the shells.
- Slide the rear main bearing casting (1) out of the cylinder block, remove and discard the bearing shell and seals.
Crankshaft Components:
- Lift the crankshaft out of the cylinder block, remove and discard the upper bearing shell halves.
REFIT
- Thoroughly clean all components and examine for wear and damage.
- Replace worn or damaged components as necessary.
- Clean all bearing surfaces and cylinder bores.
- Fit new sealing strips to the grooves of the rear main bearing casting.
- Remove the rear main bearing casting.
- Liberally oil the upper main bearing shells and fit to the cylinder block.
- Smear the rear oil seal with Dag Colloidal Graphite.
NOTE: The center and rear bearing shells cannot be interchanged; the rear main bearing shell has an oil groove, the center main bearing shell is of plain construction.
- Position the crankshaft in the cylinder block.
- Liberally oil the main bearing cap shells and fit to the main bearing caps.
- Fit the caps to the crankshaft, fit and tighten the securing nuts and pillar nuts.
NOTE: It is not necessary to fit the center bearing cap prior to checking the crankshaft end float.
Thrust Washers:
- Check the crankshaft end float. Should be:
O.OO4-.OO6in (O.1-.15 mm)
- Thrust washers are available in sizes O.1O1-.1O3 in (2.57-2.62 mm). Fit the selected washers to the groove in the cylinder block (2).
NOTE: The grooved side of the thrust washers must face outwards.
- Recheck the end float. Adjust as necessary.
- Lubricate and fit the center main bearing cap, fit and tighten the securing nuts.
NOTE: Be sure the reference marks on the caps align with the marks on the cylinder block.
- Fit a new bearing shell half into the connecting rod, ensuring that the bearing shell tab is correctly located in the connecting rod.
- Coat the bearing shell with oil. Pull the connecting rod down on to the crankshaft journal.
- Coat the connecting rod cap bearing surface liberally with clean engine oil.
- Fit a new bearing shell half into the connecting rod cap, ensuring that the bearing shell tab is correctly located.
- Coat the bearing shell with oil. Fit the connecting rod cap. Fit and torque tighten the securing nuts.
- Repeat the procedure to refit the remaining piston/connecting rod assemblies.
- Refit the oil pump drive gear, Woodruff key and oil pump.
- Fit and tighten the securing bolts.
- Fit a new Woodruff key to the crankshaft and refit the crankshaft sprocket.
- Refit the undershield.
- Refit the delivery pipe elbow, using a new O-ring.
- Refit the delivery pipe/undershield.
- Refit the suction pipe, using a new O-ring.
- Clean the oil strainer.
- Refit the sandwich plate assembly.
- Refit the oil pan.
- Refit the timing chain and tensioner assembly.
- Refit the timing cover, using a new oil seal.
- Check/adjust the valve clearances.
- Refit the cylinder heads.
- Refit the camshaft covers.
- Refit the induction manifolds.
- Refit the drive plate and torque converter.
- Refit the fan/clutch assembly.
- Refit the engine/transmission assembly.
- Refit the oil pan plug, using a new washer and refill the engine with clean oil.
- Refill the cooling system.
TORQUE FIGURES
Air pump adjuster bolt/locknut 20-27 Nm
Banjo connector bolts 12-14 Nm
Camshaft sprocket to camshaft 23-27 Nm
Camshaft cover 11 Nm
Connecting rod cap nuts 54-55.5 Nm
Cylinder head to block (9/16"AF) 36 Nm
Cylinder head to block (5/8 "A F) 70 Nm
EGR valve to throttle housing 9.5-12 Nm
Elbow to inlet manifold 12.2 Nm
Engine mounting bracket to crossmember 19-24 Nm
Engine mounting tie bolts 34-4O Nm
Exhaust down pipe to manifold 30-35 Nm
Fan/clutch to water pump 23-27 Nm
Flywheel bolts 90 Nm maximum
Fuel pipe unions (5/16" dia.) 8.5-9.5 Nm
Fuel pipe unions (3/8" dia.) 11-13.5 Nm
Fuel pipe unions (1/2" dia.) 27-33 Nm
Heat shield to manifold 23-27 Nm
Hose clips 2.5 Nm
Inlet manifold to cylinder head (nuts) 23-27 Nm
In let manifold to cylinder head (bolts) 23-27 Nm
Main bearing cap nuts (1/2") 84 Nm maximum
Main bearing cap nuts (3/8") 36.5-38 Nm
Oil cooler pipes 54-6O Nm
PAS pump to mounting bracket 50 Nm
Propeller shaft bolts 36.5-43 Nm
Rear engine mounting peg 34-40 Nm
Rear engine mounting rubbers 35-43 Nm
Rear engine mounting to body (5/16 bolt) 19-24 Nm
Rear engine mounting to body (3/8 bolt) 35-43 Nm
Sandwich plate to block 16.5-21 Nm
Silencer to compressor union 34 Nm
Sump drnin plug 15-18 Nm
Sump set screws 16-20 Nm
Torque converter bolts 55-62 Nm
Thermostat housing to cylinder head 23-27 Nm