Crankshaft, Remove and Install
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Engine cylinder/bearing numbering starts from flywheel end.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine - see operation Engine with Transmission, Remove and Install.
Transmission from engine - six bolts.
Transfer engine from hoist to stand.
Drain engine oil.
Timing belt - see corresponding operation.
| Transmission cooler hoses and support bracket. | |||
|---|---|---|---|
| .P. T3344.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Starter motor.
| Dipstick. | |||
|---|---|---|---|
| .P. T3209.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Clutch assembly from flywheel- bolts.
Flywheel from crankshaft - see corresponding operation.
| Invert engine. | |||
|---|---|---|---|
| .P. T3308.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Oil pan and gasket from cylinder block - bolts and washers.
| Oil pump and filter from cylinder block - bolts. | |||
|---|---|---|---|
| .P. T3183.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Con-rod bearing caps - bolts.
Con-rod bearing shells.
Identify con-rod bearing cap and con-rod with cylinder number, if necessary.
| Cylinder block only shown for clarity. | |||
|---|---|---|---|
| .P. T3184.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Crankshaft front oil seal housing- bolts.
Crankshaft rear oil seal.
Crankshaft.
Bearing shells.
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Clean |
All parts.
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
|---|---|---|---|
| Crankshaft and bearing shells - see operation Crankshaft, Check. | |||
| .P. T3191.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Bearing shells to cylinder block and caps (those with oil grooves fit the block and plain shells fit the caps).
Crankshaft to cylinder block - lubricate bearing surfaces with clean engine oil.
On main bearing number 2, crankshaft thrust bearings are to be installed with oil grooves (A) towards the crankshaft.
Engine cylinder/bearing numbering starts from flywheel end.
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
|---|---|---|---|
| Crankshaft axial play - see operation Crankshaft Check. | |||
| .P. T3192.tif | 9 | 7,5 | tiff;; |
Rear main bearing sealing is effected by silicone sealant or butyl seals.
Silicone sealant
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Clean |
Degrease jointing area of number 6 main bearing.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Place a thin coating of silicone sealant at B on rear main bearing number 6 and insert bolts.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Main bearing bolts - 65 Nm/48 lbf ft. | |||
| .P. T3193.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Fill vertical seal grooves in main bearing cap, ensuring sealant fills joint, then when set, cut off surplus. | |||
| .P. T3194.tif | 9 | 7,5 | tiff;; |
Butyl seals
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Groove dimension by using drill bit.
If groove is less than or equal to 5 mm, select seal without colour marking 5.1 mm thick.
| If groove is more than 5 mm, select seal with colour marking 6.0 mm thick. | |||
|---|---|---|---|
| .P. T3195.tif | 9 | 7,5 | tiff;; |
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Clean |
Degrease jointing area on number 6 main bearing as for silicone sealant.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Place a thin coating of silicone sealant on rear main bearing cap recess on horizontal joint faces.
Lubricate seals and place them in main bearing cap and with 2 guide studs (10 mm x
| 1.5 mm pitch); slide bearing cap down into position, ensuring that butyl seals are still protruding below cap to contact silicone sealant to ensure full sealing. | |||
|---|---|---|---|
| .P. T3196.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Guide studs.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Main bearing bolts.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Main bearing bolts - 65 Nm/48 lbf ft.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
|---|---|---|---|
| Cut off surplus seal protruding from joint. | |||
| .P. T3197.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Crankshaft rear oil seal into main bearing cap recess - use Installer KM-6029. | |||
| .P. T3198.tif | 9 | 7,5 | tiff;; |
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Clean |
Degrease jointing area on front seal mounting plate.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
|---|---|---|---|
| Place a thin coating of silicone sealant on jointing areas, take care not to block oil hole C. | |||
| .P. T3199.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Crankshaft front oil seal into housing - use Installer KM-6028. | |||
| .P. T3200.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Con-rod bearing shells - apply clean engine oil to shells.
| Con-rod bearing caps - apply clean engine oil to threads and contact surface of con-rod cap bolts; align number etched on cap (arrowed) with same number on con-rod. | |||
|---|---|---|---|
| .P. T3184.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Oil pick-up and filter - bolts.
Oil pan and gasket - bolts and washers.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Oil pan bolts - 14 Nm/10 lbf ft. | |||
| .P. T3183.tif | 9 | 7,5 | tiff;; |
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Con-rod cap bolts 48 Nm/35 lbf ft.
Ensure crankshaft rotates smoothly.
| Invert engine. | |||
|---|---|---|---|
| .P. T3186.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Flywheel to crankshaft - see corresponding operation.
Clutch assembly to flywheel - bolts.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Clutch to flywheel bolts - 25 Nm. | |||
| .P. T3308.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Dipstick.
| Starter - see corresponding operation. | |||
|---|---|---|---|
| .P. T3209.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Timing belt - see corresponding operation.
Transmission cooler hoses and support bracket.
Transfer engine from hoist to stand.
Transmission to engine - six bolts.
Engine - see operation Engine with Transmission, Remove and Install.
Refill engine with oil.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Transmission to engine bolts - 30 Nm. | |||
| .P. T3344.tif | 9 | 7,5 | tiff;; |