Removal and Replacement

CRANKSHAFT

REMOVAL
1. Remove engine from vehicle.
2. Mount engine on an engine stand.
3. Drain engine oil and remove oil filter.
4. Remove oil pan and oil pick-up tube.
5. Remove idler pulley bracket for accessory drive belt.
6. Remove upper intake manifold.
7. Remove cylinder head covers.
8. Remove timing chain cover.
9. Remove primary timing chain.
10. Remove crankshaft sprocket.
11. Remove oil pump.
12. Remove crankshaft rear oil seal retainer.

Fig. 53:

13. Remove structural windage tray (Fig. 53).
14. Turn crankshaft until connecting rod cap to be removed is accessible.

NOTE: Connecting rod bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly.

CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.

15. Mark connecting rod bearing cap positions using a permanent ink marker or scribe tool.
16. Remove connecting rod bearing caps. Use care to prevent damage to the crankshaft bearing surfaces.

CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or damage to the engine may occur.

Fig. 54:

17. Remove main bearing cap bolts and tie bolts (Fig. 54).
18. Remove main bearing caps (Fig. 54).

CAUTION: When removing crankshaft, use care not to damage bearing surfaces on the crankshaft

Fig. 55:

19. Remove crankshaft from cylinder block (Fig. 55).

INSTALLATION

NOTE: Upper and lower bearing halves are NOT interchangeable.

CAUTION: Main bearings are select fit.

Fig. 56:

1. Lubricate upper main bearing halves with engine oil (Fig. 56).

CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft.

2. Install crankshaft (Fig. 55).

NOTE: Make sure that the coated and oil groove side of crankshaft thrust washer faces the crankshaft thrust surface.

Fig. 57:

3. Push crankshaft forward. Lubricate and install the front thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface (Fig. 57).
4. Move crankshaft rearward. Lubricate and install the rear thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface.

5. Lubricate lower main bearings with engine oil.
6. Install main bearings and caps.

NOTE: Lubricate main bearing cap bolts with engine oil before installation. The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, and lastly the main cap tie (horizontal) bolts.

7. Install the inside main bearing cap bolts and tighten to 20 Nm + 1/4 Turn (15 ft. lbs.). + 1/4 Turn) (Fig. 54).
8. Measure crankshaft end play.
9. Install connecting rods and measure side clearance.
10. Install windage tray (Fig. 53). Lubricate bolts with engine oil and tighten to 27 Nm + 1/4 Turn (20 ft. lbs.). + 1/4 turn).
11. Install the main cap tie (horizontal) bolts and tighten to 28 Nm (250 inch lbs.). (Fig. 54).
12. Install rear crankshaft oil seal retainer and oil seal.
13. Install oil pump assembly.
14. Install crankshaft sprocket.
15. Install timing chain.
16. Install timing chain cover.
17. Install cylinder head covers.
18. Install idler pulley bracket for accessory drive belt.
19. Install oil pick-up tube and O-ring.
20. Install oil pan and oil filter.
21. Install oil dipstick tube.
22. Install engine assembly.
23. Fill engine crankcase with proper oil to correct level.