Loosen the bearing cap bolts and the bearing cap side bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
2.
Remove the bearing cap bolts (A) and the bearing cap side bolts (B), then remove the main bearing caps (C).
10.
Crankshaft - Remove
1.
Lift the crankshaft (A) out of the engine block, being careful not to damage the journals and the CKP pulse plate (B).
2.
Remove the thrust washers (C).
3.
Reinstall the main bearing caps and bearings on the engine block in the proper order.
11.
CKP Pulse Plate - Remove
1.
Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
2.
Check the keyway slot and the threaded holes for damage.
3.
Remove the CKP pulse plate (A).
NOTE: Be careful not to damage the journals and the CKP pulse plate.
1.
Crankshaft - Inspect
Out-of-Round and Taper
1.
Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
2.
Check the keyway slot and the threaded holes for damage.
3.
Measure the out-of-round at the middle of each rod and the main journal in two places. The difference between measurements on each journal must not be more than the service limit.
Journal Out-of-Round
Standard (New):
0.005 mm (0.00020 in) max.
Service Limit:
0.010 mm (0.00039 in)
4.
Measure the taper at the edges of each rod and main journal. The difference between measurements on each journal must not be more than the service limit.
Journal Taper
Standard (New):
0.005 mm (0.00020 in) max.
Service Limit:
0.010 mm (0.00039 in)
Straightness
5.
Place the V-blocks on a flat surface.
6.
Check the total runout with the crankshaft supported on V-blocks.
7.
Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit.
Tighten the main bearing cap bolts, then tighten the main bearing cap side bolts to the specified torque in the sequence as shown. Repeat the torque sequence again to ensure the bolts are properly torqued.
2.
Remove all of the old liquid gasket from the engine block end cover mating surfaces, the bolts, and the bolt holes.
3.
Clean and dry the engine block end cover mating surfaces and the crankshaft oil seal housing.
4.
Apply a light coat of new engine oil to the lip of the crankshaft oil seal.
8.
Crankshaft Oil Seal - Install (Engine Block End Cover)
Using the driver handle, 15 x 135L and the oil seal driver attachment, 106 mm, drive in the new crankshaft oil seal (A) until the oil seal driver attachment bottoms on the engine block end cover.
9.
Engine Block End Cover - Install
1.
Apply liquid gasket (P/N 08717-0004, 08718-0003, 08718-0004, or 08718-0009) to the engine block mating surface of the engine block end cover and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
2.
Install the dowel pins (A), a new O-ring (B), and the engine block end cover (C) on the engine block.
NOTE:
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the engine block end cover.
3.
Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
Apply liquid gasket (P/N 08717-0004, 08718-0003, 08718-0004, or 08718-0009) to the engine block mating surface of the oil pump and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
2.
Apply a light coat of new engine oil to the lip of the crankshaft oil seal, and to the new O-ring (A).
3.
Install the dowel pins (B), then align the inner rotor with the crankshaft, and install the oil pump (C).
NOTE:
Wait at least 30 minutes before filling the engine with oil.
Do not run the engine for at least 3 hours after installing the engine block end cover and the oil pump.
4.
Clean the excess oil off the crankshaft, and check that the oil seal lip is not distorted.
12.
Engine Oil Strainer and Baffle Plate - Install
1.
Install the baffle plate (A).
2.
Install the oil strainer (B) with a new O-ring (C).
13.
Oil Filter Base/Oil Filter Assembly - Install
Install the oil filter base/oil filter assembly (A) with a new O-ring (B).
