REMOVAL & INSTALLATION
See Figures 1 and 2
When draining coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
2.0L and 2.3L Engine
- Disconnect the negative battery cable.
- Drain the cooling system and engine crankcase.
- Remove the engine from the vehicle.
- Remove the crankshaft front pulley, front cover, timing chain and sprockets, cylinder head, oil pan, oil pump and intermediate driveshaft.
- Remove the rear oil seal cover bolts and remove the cover.
- Remove the piston assemblies.
Mark the connecting rods and bearing caps so they can be installed in the proper cylinders.
- Remove the main bearing caps and bearing.
- Carefully lift the crankshaft out of the crankcase, so No. 3 thrust bearing surfaces are not damaged.
- Remove the main bearing inserts from the engine block and bearing caps.
For cleaning purposes, the oil gallery and coolant drain plugs can be removed.To install:
- Wash the cylinder block thoroughly to remove all foreign material and dry before assembling other components. Check to ensure all oil holes are fully open and clean. Check to ensure the bearing inserts and bearing bores are clean. Clean the mating surfaces of the crankcase and each main bearing cap.
- Install the main bearings in the cylinder block. Note that the center front bearing is a thrust bearing and the front upper bearing has a small "V'' notch on the parting line face.
- Lubricate the bearings with clean engine oil.
- Carefully lower the crankshaft into place. Be careful not to damage the bearing surfaces.
- Check the clearance of each main bearing as outlined in this section.
- After the bearing has been fitted, apply a light coat of engine oil to the journal and bearings. Install the bearing cap in their original locations . (refer to numbers on caps). The caps must be installed with the arrows pointing to ward the front of the engine. Oil the bolts and tighten to specifications. Repeat the procedure for the remaining bearings.
Turn the crankshaft to check for turning torque. The turning torque should not exceed 4.5 ft. lbs. (6 Nm).
- Install the pistons and connecting rod caps. Check clearance of each bearing, as out lined in this section.
- After the connecting rod bearings have been fitted, apply a light coat of engine oil to the journal and bearings.
- Turn the crankshaft throw to the bottom of its stroke. Pull the piston all the way down until the rod bearing seats on the crankshaft journal.
Guide the rod to prevent crankshaft journal and oil cooling jet damage.
- Install the connecting rod cap. Align the marks on the rods with the marks on the cap, and tighten the nut.
- After the piston and connecting rod assemblies have been installed, check the side clearance between the connecting rods on each connecting rod crankshaft journal.
- Install the rear crankshaft seal and cover. Tighten the bolts to 5-7 ft. lbs. (7-10 Nm).
- Install the intermediate driveshaft, oil pump, timing chain and sprockets, front cover, crankshaft pulley and cylinder head.
- Install the engine in the vehicle.
- Fill the crankcase with the recommended engine oil. Fill and bleed the cooling system.
- Connect the negative battery cable.
- Run the engine and check for leaks.
- With the engine removed from the vehicle and placed on a workstand, loosen the idler pulley and the alternator belt adjusting bolt.
- Remove the oil pan and gasket.
- Remove the front cover assembly.
- Check the timing chain deflection. Remove the timing chain and sprockets.
- Invert the engine on the workstand. Remove the flywheel. Remove the oil pump inlet and the oil pump assembly.
- Ensure all bearing caps (main and connecting rod) are marked so that they can be installed in their original positions. Turn the crankshaft until the connecting rod from which the cap is being removed is up. Remove the connecting rod cap. Push the connecting rod and piston assembly up in the cylinder. Repeat the procedure for the remaining connecting rod assemblies.
- Remove the main bearing caps.
- Carefully lift the crankshaft out of the block so that the upper thrust bearing surfaces are not damaged.
If the bearings are to be reused they should be identified to ensure that they are installed in their original positions.
- Remove the main bearing inserts from the block and bearing caps.
- Remove the connecting rod bearing inserts from the connecting rods and caps.
- Inspect all the machined surfaces on the crankshaft for nicks, scratches, scores, etc., which could cause premature bearing wear.
- If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize bearings, usually in 0.25mm, 0.50mm, 0.80mm undersize.
Ensure the bearing inserts and the bearing bores are clean. Foreign material under the inserts will distort the bearing and cause a failure.
- Place the upper main bearing inserts in position in the bores with the tang fitted in the slot provided.
- Install the lower main bearing inserts in the bearing caps.
- Carefully lower the crankshaft into place.
- Check the clearance of each main bearing. Select fit the bearings for proper clearance.
- After the bearings have been fitted, apply a light coat of Oil Conditioner part No. D9AZ-19578-CO or heavy engine oil, SAE 50 weight, to the journals bearings and rear seal surface. Install all the bearing caps. Apply RTV to the gap between the rear main bearing and the block. Take care to keep RTV from the parting surfaces between the block and the cap.
Ensure the main bearing caps are installed in their original positions and orientation.
- Lubricate the journal with oil conditioner or heavy engine oil 50 SAE weight. Install the thrust bearing cap with the bolts finger-tight. Pry the crankshaft forward against the thrust surface of the upper half of the bearing. Hold the crankshaft cap to the rear. This will align the thrust surfaces of both halves of the bearing to be positioned properly. Retain the forward pressure on the crankshaft. Tighten the cap bolts to 65-81 ft. lbs. (85-105 Nm).
- Check the crankshaft end-play with a dial indicator mounted on the front of the engine.
- If the end-play exceeds specification, replace the upper and lower thrust bearings. If the end-play is less than specification, inspect the thrust bearing faces for damage, dirt or improper alignment. Install the thrust bearing and align the faces. Recheck the end-play.
- Install the new bearing inserts in the connecting rods and caps. Check the clearance of each bearing by using a piece of Plastigauge®.
- If the bearing clearances are to specification, apply a light coat of Oil Conditioner part No. D9AZ-19579-C or heavy engine oil, SAE 50 weight, to the journals and bearings.
- Turn the crankshaft throw to the bottom of the stroke. Push the piston all the way down until the rod bearings seat on the crankshaft journal.
- Install the connecting rod cap.
- After the piston and connecting rod assemblies have been installed, check all the connecting rod crankshaft journal clearances using a piece of Plastigauge®.
- Turn the engine on the work stand so that the front end is up. Install the timing chain, sprockets, front cover, new oil seal and crankshaft pulley.
- Turn the engine on the work stand so that the rear end is up. Install the rear oil seal.
- Clean the oil pan, oil pump and the oil pump screen assembly.
- Prime the oil pump by filling the inlet opening with oil and rotating the pump shaft until the oil emerges from the outlet opening. Install the oil pump, baffle and oil pan.
- Position the flywheel on the crankshaft. Tighten to 54-64 ft. lbs. (70-83 Nm).
- Turn the engine on work stand so that the engine is in the normal upright position. Install the accessory drive pulley. Install and adjust the accessory drive belts to specification.
- Install the torque converter, as required.
- Remove the engine from the work stand. Install the engine in the vehicle.
CLEANING AND INSPECTION
- Handle the crankshaft with care to avoid possible fractures or damage to the finish surface.
- Clean the crankshaft with solvent, and blow out all passages with compressed air.
- Inspect the main and connecting rod journals for cracks, scratches, grooves or scores.
- Measure the diameter of each journal at least 4 places to determine out-of-round, taper or undersize conditions.
- Dress minor scores with an oil stone. If the journals are severely marred or exceed the service limit, they should be refinished to size for the next undersize bearing. If the journal will not clean up to maximum undersize bearing available, replace the crankshaft.
- Force the crankshaft toward the rear of the engine.
- Install a dial indicator so that the contact point rests against the crankshaft end and the indicator axis is parallel to the crankshaft axis.
- Zero the dial indicator. Push the crank shaft forward and note the reading on the dial.
- If the end-play exceeds specification, replace the No. 3 main bearing.
FITTING BEARINGS WITH PLASTIGAUGE®
See Figure 2
- Clean the crankshaft journals. Check to ensure the journals and thrust bearing faces and free of nicks, burrs or bearing puck-up that would cause premature bearing wear.
- When fitting a main bearing, position a jack under the counterweight adjoining the bearing which is being checked. Support the crankshaft with the jack so its weight will not compress the Plastigauge® and provide an erroneous reading.
Do not place the jack under the front post of the crankshaft.
- Place a piece of Plastigauge® on the bearing surface across full width of the bearing cap and about 1 / 4 in. (6mm) off center.
- Install the cap and tighten bolts to specification cation. Do not turn the crankshaft while the Plastigauge® is in place.
- Remove the cap. Using the Plastigauge® scale, check width of the Plastigauge® at widest point to get minimum clearance. Check narrow est point to get maximum clearance. Difference between readings is taper of journal.
- After the bearing has been fitted, apply a light coat of engine oil to the journal and bearings. Install the bearing cap. Tighten to specifications. Repeat the procedure for the remaining bearings.
BEARING OIL CLEARANCE
Remove the cap from the bearing to be checked. Using a clean, dry rag, thoroughly clean all oil from the crankshaft journal and bearing insert.
Plastigauge® is soluble in oil, therefore, oil on the journal or bearing could result in false readings.
Place a piece of Plastigauge® along the full width of the bearing insert, reinstall cap, and torque to specifications.
Remove the bearing cap, and determine bearing clearance by comparing width of the bearing insert, reinstall cap, and torque to specifications.
Do not rotate crankshaft with Plastigauge® installed. If the bearing insert and journal appear intact, and are within tolerances, no further main bearing service is required. If the bearing or journal appear defective, cause of failure should be determined before replacement.
If a journal is damaged on the crankshaft, repair is possible by having the crankshaft machined to a standard undersize.
In most cases, however, since the engine must be removed from the car and disassembled, some thought should be given to replacing the damaged crankshaft with a reground shaft kit. A reground crankshaft kit contains the necessary main and rod bearings for installation. The shaft has been ground and polished to undersize specifications and will usually hold up well if installed correctly.