Crankshaft

Removal

1. With engine removed from vehicle and placed on a work stand, drain the crankcase and cylinder block. Disconnect the spark plug wires at the spark plugs and remove the wires from the ignition harness brackets on the valve rocker arm covers. Remove the distributor cap and spark plug wire assembly. Remove the spark plugs to allow easy rotation of the crankshaft.

2. Remove the oil filter. Slide the water pump bypass hose clamp toward the water pump. Remove the accessory brackets attached to the front cover and water pump.

3. Remove the crankshaft pulley from the crankshaft vibration damper. Remove the cap screw and washer from the end of the crankshaft. Install the puller on the crankshaft vibration damper and remove damper.

4. Remove the cylinder front cover and water pump as an assembly.

5. Check the timing chain deflection. Refer to Section 03-00. Remove the timing chain and sprockets.

6. Invert the engine on the work stand. Remove the clutch pressure plate and disc (manual transmission). Remove the flywheel and engine rear cover plate. Remove the oil pan and gasket. Remove the oil pump.

7. Ensure all bearing caps (main and connecting rod) are marked so that they can be installed in their original locations.

8. Turn the crankshaft until the connecting rod from which the cap is being removed is down, and remove the bearing cap. Push the connecting rod and piston assembly up into the cylinder. Repeat this procedure until all the connecting rod bearing caps are removed.

9. Remove the main bearing caps.

    CAUTION: Handle the crankshaft with care to avoid possible fracture or damage to the finished surfaces.

10. Carefully lift the crankshaft out of the block so that the thrust bearing surfaces are not damaged.

11. To refinish journals, dress minor imperfections, etc., refer to Section 03-00.
    
    
    
    
    

    Item	Part Number	Description
    1	388813	Bolt 5/8-18
    2	6378	Damper Washer
    3	6312	Crankshaft Pulley
    4	6316	Crankshaft Damper
    5	6306	Crankshaft Sprocket
    6	388907	Crankshaft Key
    7	6300	Crankshaft
    8	6333	Crankshaft Main Upper Bearing
    9	6337	Crankshaft Main Upper Thrust Bearing
    10	6375	Flywheel Assy
    11	6701	Rear Oil Seal
    12	6A388	Crankshaft Main Lower Bearing
    13	6A339	Crankshaft Main Lower Thrust Bearing
    14	6325	Main Bearing Rear Cap
    15	6327	Main Bearing Rear Intermediate Cap
    16	6330	Main Bearing Center Cap
    17	6334	Main Bearing Front Intermediate Cap
    18	6329	Main Bearing Front Cap
    19	386562	Main Bearing Cap Stud
    20	391288	Main Bearing Cap Bolt (9 Req'd)
    21	—	Bolt (4 Req'd)

Installation

1. Remove the main bearing inserts from the block and bearing caps.

2. Remove the connecting rod bearing inserts from the connecting rods and caps.

3. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize bearings. If not, ensure the bearing inserts and bearing bores are clean. Foreign material under the inserts will distort the bearing and cause a failure.

    CAUTION: Be careful not to damage the bearing surfaces.

4. Place the upper main bearing inserts in position in the bores with the tang fitting in the slot provided.

5. Install the lower main bearing inserts in the bearing caps.

6. Clean the mating surfaces of the block and rear main bearing cap.

7. Carefully lower the crankshaft into place.

8. Check the clearance of each main bearing following the procedure under Fitting Main and Connecting Rod Bearings in Section 03-00.

    CAUTION: Ensure main bearing caps are installed in their original locations. Tighten the bearing cap bolts to 81-95 Nm (60-70 lb-ft).

9. After the bearings have been fitted, apply a light coat of engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent to the journals and bearings. Install the rear main bearing cap by following Steps 7, 8 and 9 under Main Bearing Installation. Install all the bearing caps, except the thrust bearing cap (No. 3 bearing).

10. Install the thrust bearing cap with the bolts finger-tight.

11. Pry the crankshaft forward against the thrust surface of the upper half of the bearing.

12. Hold the crankshaft forward and pry the thrust bearing cap to the rear. This will align the thrust surfaces of both halves of the bearing.

13. Retain the forward pressure on the crankshaft. Tighten the cap bolts to 81-95 Nm (60-70 lb-ft).

14. Force the crankshaft toward the rear of the engine.

15. Check the crankshaft end play. Refer to Section 03-00.

16. Install new bearing inserts in the connecting rods and caps. Check the clearance of each bearing following the procedure under Fitting Main and Connecting Rod Bearings in Section 03-00.

17. After the connecting rod bearings have been fitted, apply a light coat of engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent to the journals and bearings.

18. Turn the crankshaft throw to the bottom of its stroke. Push the piston all the way down until the rod bearing seats on the crankshaft journal.

19. Install the connecting rod cap. Tighten the nuts to 26-32 Nm (19-24 lb-ft).

20. After the piston and connecting rod assemblies have been installed, check the side clearance between the connecting rods and each connecting rod crankshaft journal.

21. Install crankshaft rear main bearing seal as outlined in this section.

22. Install the timing chain and sprockets, cylinder front cover and crankshaft pulley and adapter, following Steps 1 through 9 under Cylinder Front Cover and Timing Chain Installation.

23. Coat the threads of the flywheel retaining bolts with oil resistant Pipe Sealant with Teflon® D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent. Position the flywheel on the crankshaft flange. Install and tighten the bolts to 102-115 Nm (75-85 lb-ft).

24. Clean the oil pan, oil pump and oil pump screen. Prime the oil pump by filling either the inlet or outlet port with engine oil XO-10W30-QSP (ESE-M2C153-E) or equivalent and rotating the pump shaft to distribute oil within the housing. Install the oil pump and oil pan as outlined.

25. Install the oil filter. Install the accessory mounting brackets. Install clutch and pressure plate (manual transmission).

26. Install the spark plugs, distributor cap and spark plug wires and high tension lead. Connect the spark plug wires and high tension lead. Refer to Section 03-07B.

27. Install the engine in the vehicle.