Removal and Replacement

CRANKSHAFT / REMOVAL
1. Remove engine from vehicle.
2. Remove oil pan.
3. Remove oil pickup tube.
4. Remove crankshaft vibration damper.
5. Remove idler pulley for accessory drive belt.
6. Remove front lower timing belt cover.
7. Remove front main timing belt cover.
8. Remove front left side timing belt cover.
9. Remove timing belt tensioner and timing belt.
10. Remove crankshaft sprocket.
11. Tap dowel pin out of crankshaft.
12. Remove oil pump assembly.
13. Remove crankshaft rear oil seal retainer.





14. Remove connecting rod bearing caps. Connecting rod bearing caps are not interchangeable and should be marked before removal to insure correct assembly (Fig. 60).





15. Remove main bearing caps. Main bearing caps are not interchangeable and are marked to insure correct assembly (Fig. 61).

Cylinder Block And Crankshaft 3.5L:

16. Remove crankshaft from cylinder block (Fig. 62).

NOTE: Before installing crankshaft, refer to Fitting Main Bearings and Installation of Connecting Rod Bearings.

INSPECTION
The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. DO NOT grind thrust faces of Number 2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.

CAUTION: With a forged steel crankshaft it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine.



INSTALLATION

CAUTION: Main bearings are select fit.





1. Install crankshaft main bearings (Fig. 63).
2. Install the crankshaft to cylinder block. (Fig. 62)





3. Move crankshaft forward to limit of travel. Lubricate and install the front thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface (Fig. 64).
4. Move crankshaft rearward to limit of travel. Lubricate and install the rear thrust washer by rolling the washer onto the machined shelf between the No. 2 upper main bulk head and crankshaft thrust surface.
5. Lubricate lower main bearings with clean engine oil.

NOTE: Lubricate main bearing cap bolts with engine oil before installation.

6. Install each main cap and tighten bolts finger tight. The main bearing cap bolts must be tightened in the proper sequence. First the inner main cap bolts, secondly the windage tray bolts, lastly the main cap tie (horizontal) bolts.
7. Install the inside main bearing cap bolts and tighten to 20 Nm (15 ft. lbs.) + 1/4 turn.
8. Measure crankshaft end play.
9. Install connecting rods and measure side clearance.
10. Install windage tray. Lubricate bolts with engine oil and tighten to 27 Nm (20 ft. lbs.) + 1/4 turn.
11. Install the main cap tie (horizontal) bolts and tighten to 28 Nm (250 in. lbs.).
12. Install rear crankshaft oil seal retainer and oil seal.
13. Install oil pump assembly.
14. Install dowel pin in crankshaft.
15. Install crankshaft sprocket.
16. Install camshaft sprockets and timing belt.
17. Install timing belt covers.
18. Install crankshaft vibration damper.
19. Install idler pulley for accessory drive belt.
20. Install oil pickup tube and tighten bolt to 28 Nm (250 in. lbs.).
21. Install oil pan.
22. Install engine assembly.
23. Fill engine crankcase with proper amount of oil.