Crankshaft: Service and Repair
Crankshaft, Renew
- Remove the engine and transmission unit from the vehicle.
- Detach the transmission unit from the engine.
- Fit the engine to a stand.
- Remove the cylinder head.
- Remove the crankshaft damper pulley assembly.
- Remove the oil pan.
- Remove the oil pump.
- Remove the flywheel (Manual), or remove the drive-plate (Automatic).
- Remove the timing cover.
- Remove the windage trays securing bolts (1 Fig. 1) and remove the windage trays (2 Fig. 1).
- Remove the timing chains - upper and lower and the upper and lower tensioners.
- Remove the seal / crankshaft damper spacer, the woodruff key (1 Fig. 2), the crankshaft sprockets (2 Fig. 2) and the inner woodruff key.
- Remove the rear oil seal housing.
- Remove the connecting rod bearing nuts and remove the connecting rod bearing caps in pairs (1-6, 2-5, 3-4), turning the crankshaft for access as required. As each connecting rod bearing cap is removed, ensure that each connecting rod and connecting rod bearing cap are identified to each other for re-pairing during assembly.
- As each cap is removed, its relative connecting rod and piston assembly should be pushed up the bore, enabling the crankshaft to be rotated to remove the remaining caps. Care should be taken not to push the piston too far up the cylinder bore as this will release the piston rings.
- Ensuring that the main bearing caps are marked re!ative to the cylinder block (1 Fig. 3), remove the main bearing cap bolts and the bearing caps, and carefully lift out the crankshaft.
- Remove and discard the bearing shells and the thrust washers.
- Clean the bearing caps and the cylinder block main bearing housings.
- Fit the new bearing shell halves to the cylinder block and lubricate with clean engine oil.
- Clean and polish the crankshaft journals, lubricate and carefully assemble the crankshaft into the cylinder block, fit the thrust washers ensuring that the steel side of the washer is mated to the cylinder block (1 Fig. 1).
- Rotate the crankshaft to ensure that it turns freely.
- Fit the main bearing shells into the main bearing caps, lubricate and fit to the cylinder block.
- Start the securing bolts and carefully tap the main bearing caps to ensure they are seated to the cylinder block.
- Rotate the crankshaft to ensure that it still turns freely, pull down each bearing cap individually and torque tighten the securing bolts.
- Rotate the crankshaft between pulling down each bearing cap.
- Check and if necessary adjust the crankshaft end-float.
- Renew the crankshaft rear oil seal.
- Fit a new bearing shell to the connecting rod, lubricate with clean engine oil and fit to the crankshaft.
- Fit a bearing shell to the connecting rod bearing cap, lubricate and fit to the connecting rod. Fit and torque tighten the nuts.
- Turn the crankshaft over ensuring that there are no `tight' spots, and that the crankshaft rotates freely.
- Repeat this procedure for the remaining five cylinders.
CAUTION: The connecting rod bearing nuts, bolts and main bearing securing bolts MUST be renewed during assembly and torque tightened as described under Engine, Service and Repair, Service Procedures, SPS Joint Control System.
- Clean and inspect for wear or damage all the timing gears, chains, guides and tensioners.
- Renew any suspect component.
- Fit and seat the crankshaft sprocket woodruff key and fit the sprocket to the crankshaft.
- Refit the timing chains - upper and lower; and the upper and lower tensioners.
- Fit a dial gauge to the top of the cylinder block and turn the engine over until No.1 and 6 pistons are at TDC (Fig. 2).
- Lubricate the upper chain and fit it to the intermediate sprocket.
- Fit an elastic band to retain the upper dampers and chain.
- Lubricate the oil pump drive chain, fit the chain to the crankshaft sprocket and lodge in the correct position.
- Renew the timing cover oil seal and refit the timing cover.
- Lubricate and fit the oil seal distance piece. Fit and seat the damper woodruff key.
- Refit the oil pump.
- Refit the flywheel (Manual), or refit the drive-plate (Automatic).
- Refit the oil pan.
- Refit the crankshaft damper/pulley assembly.
- Refit the cylinder head.
- Remove the engine from the stand and refit the transmission unit.
- Refit the engine/transmission unit to the vehicle.